Device and method for inserting flat wire hairpins into stator

Abstract

The invention discloses a device and a method for inserting flat wire hairpins into a stator. The device comprises a rack and a hairpin placing mold. The mold comprises a charging barrel, a pluralityof baffle plates which are arranged on the barrel wall of the charging barrel and can stretch out and draw back in the radial direction of the charging barrel, an elastic element which is used for forcing the baffle plates to draw back to an inner cavity of the charging barrel, a mandrel pull rod which is used for making the baffle plates stretch out of the charging barrel, and a hairpin push sleeve which sleeves the charging barrel. The baffle plates form a hairpin placing groove in the periphery of the charging barrel, and the hairpin placing groove is used for placing all flat wire hairpinsrequired by a stator core. The push sleeve is used for pushing all the flat wire hairpins placed on the periphery of the charging barrel forwards, so that all the flat wire hairpins are pressed intothe hairpin slots of the stator core. Through a layer-by-layer placing mode, formed hairpins are placed into the mold and then integrally inserted into the stator core, so that scratching between adjacent flat wires caused by an existing one-by-one insertion mode is avoided.

Description

technical field [0001] The invention relates to the field of flat wire motors for new energy vehicles, in particular to a device and method for inserting a flat wire hairpin (H-pin) into a stator. Background technique [0002] Because of its flat structure, the flat copper wire motor can greatly increase the full rate of the motor slot, thereby increasing the power density of the motor, and the failure rate of the flat copper wire motor can also be reduced. Therefore, the flat copper wire is currently used in the field of motors. More and more, however, if the installation and processing of flat copper wires cannot meet the needs of the motor or the processing precision is not high and the processing difficulty is high, it will also lead to a reduction in the production efficiency of the motor, and the low precision will lead to a decrease in the efficiency of the subsequent use of the motor Therefore, for the flat copper wire motor, the effect of the installation and proces...

AI Technical Summary

Problems solved by technology

[0002] Because of its flat structure, the flat copper wire motor can greatly increase the full rate of the motor slot, thereby increasing the power density of the motor, and the failure rate of the flat copper wire motor can also be reduced. Therefore, the flat copper wire is currently used in the field of motors. More and more, however, if the installation and processing of flat copper wires cannot meet the needs of the motor or the processing precision is not high and the processing difficulty is high, it will also lead to a reduction in the production efficiency of the motor, and the low precision will lead to a decrease in the efficiency of the subsequent use of the motor Great discount, therefore, for the flat copper wire motor, the installation and processing effect of the flat copper wire directly affects the performance of the motor

[0003] In the existing technology, most of the wires are inserted manually one by one. This method not only takes a long time to process, but also requires a lot of manpower to complete, and the quality of the produced products is also unstable; there is also a method of automatically inserting the wires one by one. The coil inserted later is easy to scratch the inserted coil and damage the insulation of enameled flat wire. If insulating paper is added between each layer, it will increase the difficulty of wire insertion, it is not easy to realize automation, and the production efficiency is low. Excessive insulating paper will reduce the slot fullness of the motor, which makes it difficult to reflect the advantages of high stator slot fullness of flat wire motors, and to some extent restricts the flexibility of winding wire size design

[0004] In the existing technology, the production efficiency of plugging is low, the degree of automation is not high, and it is difficult to ensure the stability of product quality

As far as the current technology is concerned, no matter whether it is automatic insertion or manual insertion, the last few sets of hairpins are very difficult to insert, and there is a risk of damaging the paint film that has been inserted into the hairpin.

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