Process calculation method and system of flat wire stator head twisting equipment and head twisting equipment

Abstract

The invention relates to the technical field of flat wire stator head twisting equipment control, and discloses a process calculation method and system of flat wire stator head twisting equipment and the head twisting equipment, and the method comprises the steps: obtaining a plurality of setting parameters of a head twisting process input by a user; calculating according to the plurality of setting parameters to obtain an operation result; inputting an operation result into a point set formula of each layer of the torsion head module to obtain a data set, wherein the point set formula comprises a parameter equation and a compensation equation of spatial displacement; and writing the data set into a control file of a preset path, and performing a head turning process on the flat copper wire after the flaring process based on the control file. According to the invention, the motion trail of the equipment is approximate to the motion trail of the copper wire bending point, the copper wire is prevented from being scratched due to large relative displacement between the head twisting die and the copper wire bending point, the process trail of the product equipment and the model changing calculation can be quickly carried out, the device can adapt to the production of flat wire products with different specifications, the production efficiency is improved, and the production cost is reduced. The processing time is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of flat wire stator twisting equipment control, and in particular to a process calculation method, system and twisting equipment of a flat wire stator twisting equipment. Background Art

[0002] Flat wire stators are key components in electric motors and play an important role in many aspects of motor performance, efficiency and compactness. Flat wire stator windings use flat wires, which are different from traditional round wire windings. These flat wires are usually closely arranged to form a specific winding layout in the stator slots.

[0003] The manufacturing process requirements of flat wire stators are much higher than those of round wire stators. The winding of flat wires requires special equipment. Because the hardness of flat wires is relatively high, the motion trajectory needs to be precisely controlled during the winding process, otherwise it is easy to cause damage to the flat wires. In the prior art, after the flat wire stator undergoes the expansion process, the flat copper wire needs to be put into a twisting die for the twisting process. During this process, the trajectory of the copper wire end and the contact point of the twisting die is a trajectory with a nonlinear relationship in circumference and height, which easily causes relative displacement between the twisting die and the copper wire, resulting in scratches on the copper wire. Summary of the invention

[0004] In view of this, the present invention provides a process calculation method, system and twisting device for a flat wire stator twisting device, which can make the motion trajectory of the device similar to the motion trajectory of the copper wire bending point, so as to avoid the problem of relative displacement between the twisting die and the copper wire causing scratches on the copper wire.

[0005] In a first aspect, the present invention provides a process calculation method for a flat wire stator twisting device, the method comprising:

[0006] Obtain multiple setting parameters of the head-turning process input by the user;

[0007] Calculate and obtain a calculation result according to the multiple setting parameters;

[0008] Inputting the calculation result into the point set formula of each layer of the twisting head mold to obtain a data set, wherein the point set formula includes a parameter equation and a compensation equation of the spatial displacement;

[0009] The data set is written into a control file of a preset path, and a twisting process is performed on the flat copper wire after the expansion process based on the control file.

[0010] The process calculation method for the flat wire stator twisting equipment provided in the embodiment of the present invention can obtain a motion trajectory that is basically consistent with the actual motion trajectory by adding a compensating spatial displacement parameter equation, thereby avoiding relative displacement between the twisting die and the copper wire, which may cause scratches on the copper wire. The process trajectory calculation of the product equipment and the changeover calculation can be performed quickly to adapt to the production of flat wire products of different specifications, save labor, and improve work efficiency.

[0011] In an optional embodiment, the multiple setting parameters of the head twisting process input by the user include: the height of each layer before bending, the span, the compensation coefficient, and the sampling accuracy, the number of stator slots, the height after bending, and the over-torque height;

[0012] The calculation results include: total stroke, over-torque cam points, end stroke points, and mirror points; where:

[0013] The total stroke is equal to the height to the end point plus the twisted height, and the height to the end point is equal to the height before bending minus the height after bending;

[0014] The number of over-torque cam points is equal to the over-torque height divided by the sampling accuracy;

[0015] The number of travel points to the end point is equal to the height to the end point divided by the sampling accuracy;

[0016] The number of mirror points is equal to the number of travel points to the end point plus the number of over-torque cam points.

[0017] The embodiment of the present invention calculates the total stroke by clarifying the height before bending, the height after bending and the over-torque height of each layer, so that the twisting process can achieve precise control in the height dimension, which helps to ensure the dimensional accuracy of the product during the twisting process; in actual production, the twisting process may produce deviations, and the setting of the compensation coefficient can correct the possible errors. The compensation coefficient can fine-tune the parameters such as the stroke according to the actual situation, thereby ensuring the stability of product quality and reducing the defective rate; the calculation of the total stroke, the number of over-torque cam points, the number of points to the end point stroke and the number of mirror points provides a detailed plan for the equipment movement of the twisting process. The equipment can reasonably arrange the movement path and action sequence according to these precise values, avoid unnecessary actions and time waste, thereby optimizing the production process and improving production efficiency; the span is used as a setting parameter, combined with other parameters, to help determine the working range and movement amplitude of the equipment during the production process. Through the given multiple parameter settings, the twisting process can adapt to the production of flat wire products of different specifications, and the setting of sampling accuracy provides a basis for the flexible adjustment of the production process. By changing the sampling accuracy, it is possible to quickly switch between production tasks with different accuracy requirements. For high-precision products, a higher sampling accuracy can be set, and the number of over-torque cam points and the number of travel points to the end point can be increased to achieve more precise processing; for products with relatively low precision requirements, the sampling accuracy can be appropriately reduced to increase the production speed.

[0018] In an optional implementation, the parameter equation of the spatial displacement is expressed as:

[0019] Z=k*Z1*(1-cosθ)

[0020] Where Z is the height displacement; Z1 is the known bending height; θ is the circumferential rotation angle;

[0021] k = 2 / (known circumferential rotation angle*π / 180) 2 ; Known circumferential rotation angle = 360*span / number of stator slots;

[0022] The compensation equation is expressed as:

[0023] Δ=Nsin(nθ)

[0024] Wherein, Δ is the height compensation; n is a parameter related to the span; n = 90 / known circumferential rotation angle; N is the compensation coefficient;

[0025] The path formed by the end height is obtained by adding the calculation result of the parameter equation of the spatial displacement to the calculation result of the compensation equation. The over-torque path formed by the over-torque height is calculated by the parameter equation of the spatial displacement. The return path formed by the mirror point number is a mirror path of the over-torque path.

[0026] The embodiment of the present invention determines the path formed to the terminal height by adding the calculation results of the spatial displacement parameter equation and the compensation equation, and fully considers the influence of various factors on the path. The spatial displacement parameter equation can describe the ideal motion trajectory of an object in space based on the basic kinematic principles, while the compensation equation can correct various interference factors in actual production. Such a combination method can make the path to the terminal height more accurate, which helps to improve the dimensional accuracy and shape accuracy of the product in the head twisting process, thereby ensuring product quality; the over-torque operation usually has a key impact on the final performance and shape of the product. The accurate over-torque path can ensure the processing quality of the product at this critical stage and avoid product defects caused by improper over-torque; the return path formed by the mirror point number is used as a mirror path of the over-torque path, which ensures the symmetry of the entire processing process. The symmetrical path helps to maintain the force balance of the product during the processing process and reduce the deformation caused by uneven force; on the other hand, from the perspective of the geometric shape and performance of the product, the symmetrical processing path helps to ensure the shape accuracy and internal stress distribution of the product, and further improves the product quality. By combining the spatial displacement parameter equation and the compensation equation to determine the height path to the end point, and rationally planning the over-torque path and return path, the overall motion trajectory of the equipment can be optimized. When the equipment performs the head-twisting process, it can move along the most reasonable path, avoiding unnecessary detours and pauses, thereby improving production efficiency and reducing processing time.

[0027] In an optional embodiment, after inputting the calculation results into the point set formula of each layer of the twisting head mold to obtain the data set, it also includes: drawing the data sets of each layer into a curve based on a drawing control, wherein the horizontal coordinate of the curve is the circumferential rotation angle, and the vertical coordinate is the height displacement.

[0028] The embodiment of the present invention converts the abstract calculation results and height displacement data into intuitive graphics by drawing the data sets of each layer into a curve display. For production personnel, they can see at a glance the height displacement of each layer of the twisting die under the change of circumferential rotation angle, so that they can better understand and grasp the details of the processing process. In terms of quality monitoring, this curve display provides a convenient basis for quality judgment. If the product has quality problems during the twisting process, such as abnormal height displacement, then the deviation from the normal curve will be shown on the curve. The curve display can be used to intuitively evaluate the effect of the process. Different process parameter settings will result in different curve shapes. Production personnel can compare the curves of different batches of products, or observe the changes in the curve after the process adjustment to determine whether the process adjustment has achieved the expected effect. The shape and characteristics of the curve can provide accurate guidance for parameter adjustment. The parameter adjustment method based on the curve is more scientific and accurate, which helps to improve the efficiency of process optimization.

[0029] In an optional implementation, before the step of obtaining a plurality of setting parameters of the head-twisting process input by the user, the step further includes:

[0030] Initialize the data structure and enter the key monitoring waiting process;

[0031] After the step of obtaining a plurality of setting parameters of the head-turning process input by the user, the method further includes:

[0032] The plurality of setting parameters are converted into a preset format and processed into a calculation process, and historical data is cleared;

[0033] Before the step of writing the data set into the control file of the preset path, the method further includes:

[0034] Gets the user-triggered control file generation signal.

[0035] The embodiment of the present invention ensures that the system is in a known and stable initial state through the initialization and monitoring settings, which facilitates the accurate execution of subsequent steps. At the same time, the key monitoring waiting process gives users the opportunity to actively participate. Users can start subsequent processes in a timely manner according to actual needs, which improves flexibility and interactivity. It obtains multiple setting parameters of the head-twisting process input by users, allowing users to set personalized parameters according to specific process requirements and product characteristics, ensuring that the head-twisting process can meet different production needs. The point set formula is a parametric equation for increasing the compensation of spatial displacement. This scientific formula application ensures the accuracy and rationality of the data and provides accurate guidance for the subsequent head-twisting process. Through the intuitive display of the trajectory curve, users can clearly understand the distribution and change trend of the data, which is convenient for users to analyze and judge, find problems in time and make adjustments. After confirming that all data and parameters are accurate, users can independently decide the time to generate the control file, and perform the head-twisting process on the flat copper wire after the expansion process based on the control file, ensuring the accurate execution of the head-twisting process and improving the reliability and stability of production.

[0036] In a second aspect, the present invention provides a process calculation system for a flat wire stator twisting device, comprising:

[0037] A parameter setting module, used to obtain multiple setting parameters of the head twisting process input by the user;

[0038] A calculation module, used for calculating and obtaining a calculation result according to the plurality of setting parameters;

[0039] A data set acquisition module, used for inputting the calculation result into the point set formula of each layer of the twisting head mold to obtain a data set, wherein the point set formula includes a parameter equation and a compensation equation of the spatial displacement;

[0040] The twisting process control module is used to write the data set into a control file with a preset path, and perform a twisting process on the flat copper wire after the expansion process based on the control file.

[0041] In a third aspect, the present invention provides a computer device, comprising: a memory and a processor, the memory and the processor are communicatively connected to each other, the memory stores computer instructions, and the processor executes the process calculation method of the flat wire stator twisting device of the above-mentioned first aspect or any corresponding embodiment thereof by executing the computer instructions.

[0042] In a fourth aspect, the present invention provides a computer-readable storage medium having computer instructions stored thereon, the computer instructions being used to enable a computer to execute the process calculation method for a flat wire stator twisting device of the first aspect or any corresponding embodiment thereof.

[0043] In a fifth aspect, the present invention provides a computer program product, including computer instructions, and the computer instructions are used to enable a computer to execute the process calculation method of the flat wire stator twisting device of the above-mentioned first aspect or any corresponding embodiment thereof.

[0044] In a sixth aspect, an embodiment of the present invention provides a flat wire stator twisting device, comprising: a wire combing mechanism, a truss, a twisting mechanism and a controller, wherein:

[0045] The electric cylinder on the thread combing mechanism can perform lifting and lowering movements;

[0046] The truss is provided with a motor, and the motor controls the wire combing mechanism to take the flat wire stator and then move to the top of the twisting mechanism;

[0047] The twisting die of the twisting mechanism is multi-layered, and each layer is provided with a servo motor. The controller controls the servo motor to drive the wire combing mechanism to lower the stator to the twisting die to put the stator copper wire into the die, and performs the twisting process based on the control file obtained by the process calculation method of the flat wire stator twisting equipment described in any one of the first aspects.

[0048] The flat wire stator twisting equipment provided in the embodiment of the present invention can be accurately adjusted according to different process requirements and parameters through the intelligent control of the controller, ensuring the accuracy and consistency of the twisting process. Through the coordinated work of various parts, an automated, efficient and precise production process is realized, which not only improves production efficiency and reduces labor intensity, but also ensures the quality stability of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0050] Figure 1 (A) is a schematic diagram of the copper wire after expansion and deformation through the twisting die to form the copper wire line shape, copper wire bending point and copper wire end;

[0051] Figure 1 (B) is a schematic diagram of the stator copper wire;

[0052] Figure 2 A schematic flow chart of a process calculation method for a flat wire stator twisting device according to an embodiment of the present invention;

[0053] Figure 3 A schematic flow chart of another process calculation method for a flat wire stator twisting device according to an embodiment of the present invention;

[0054] Figure 4 A schematic flow chart of a process calculation method for a flat wire stator twisting device according to a specific example of an embodiment of the present invention;

[0055] Figure 5 A schematic diagram of a user interaction interface according to an embodiment of the present invention;

[0056] Figure 6 A schematic diagram of padding data in a control file according to an embodiment of the present invention;

[0057] Figure 7 A structural block diagram of a process calculation system for a flat wire stator twisting device according to an embodiment of the present invention;

[0058] Figure 8 A structural block diagram of a process calculation system for another flat wire stator twisting device according to an embodiment of the present invention;

[0059] Fig. 9 is a schematic diagram of the hardware structure of a computer device according to an embodiment of the present invention;

[0060] Fig.10 It is a schematic structural diagram of a flat wire stator twisting device according to an embodiment of the present invention.

[0061] Reference numerals:

[0062] 1-combing mechanism; 2-truss; 3-head twisting mechanism; 301-head twisting mold. DETAILED DESCRIPTION

[0063] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention.

[0064] Flat wire stators are key components in motors and play an important role in motor performance, efficiency and compactness. Flat wire stators are wound with flat wires, which are different from traditional round wire windings. These flat wires are usually closely arranged to form a specific winding layout in the stator slots. For example, in the flat wire stators of some automotive drive motors, the winding is formed by inserting the flat wires into the stator slots in a specific order and twisting and connecting them at the ends to form a double-layer or multi-layer winding structure.

[0065] Because the hardness of the flat wire is relatively high, the winding tension and bending radius need to be precisely controlled during the winding process, otherwise it is easy to cause damage to the flat wire. Figure 1 As shown in (A), the bending point of the copper wire does not change relative to the end of the copper wire. Assuming that the stator is Figure 1 (B) is not moving, which requires that the twisting die has circumferential and height displacements in the process of driving the copper wire to twist. If these two displacements move in a linear relationship, it will cause a large relative displacement between the twisting die and the bending point of the copper wire, resulting in scratches on the copper wire. In order to make the process motion trajectory of the twisting die basically consistent with the actual situation and improve product quality and reliability, the present invention provides a process calculation method for a flat wire stator twisting device, which can quickly calculate the process trajectory of the product equipment and perform the conversion calculation, improve production efficiency, and avoid large relative displacement between the twisting die and the bending point of the copper wire, resulting in scratches on the copper wire.

[0066] According to an embodiment of the present invention, an embodiment of a process calculation method for a flat wire stator twisting device is provided. It should be noted that the steps shown in the flowchart of the accompanying drawings can be executed in a computer system such as a set of computer executable instructions, and although a logical order is shown in the flowchart, in some cases, the steps shown or described can be executed in an order different from that shown here.

[0067] In this embodiment, a process calculation method for a flat wire stator twisting device is provided. Figure 2 is a flow chart of a process calculation method for a flat wire stator twisting device according to an embodiment of the present invention. Figure 2 As shown, the process includes the following steps:

[0068] S101, obtaining multiple setting parameters of the head twisting process input by the user.

[0069] Specifically, a user interaction interface can be set to allow users (such as production personnel) to set personalized parameters according to specific process requirements and product characteristics, ensuring that the twisting process can meet different production needs. In the embodiment of the present invention, the twisting die of the flat wire stator twisting equipment is 8 layers as an example, and the user input setting parameters include: the height before bending, span, compensation coefficient, sampling accuracy, number of stator slots, height after bending, and over-torque height of each layer.

[0070] The embodiment of the present invention calculates the total stroke by clarifying the height before bending, the height after bending and the twisting height of each layer, so that the twisting process can be precisely controlled in the height dimension, which helps to ensure the dimensional accuracy of the product during the twisting process; in actual production, the twisting process may produce deviations, and the setting of the compensation coefficient can correct possible errors. The compensation coefficient can fine-tune parameters such as the stroke according to actual conditions, thereby ensuring the stability of product quality and reducing the defective rate; the span and the number of stator slots are used as setting parameters, combined with other parameters, to help determine the working range and movement amplitude of the equipment during the production process; the setting of the sampling accuracy provides a basis for the flexible adjustment of the production process. By changing the sampling accuracy, it is possible to quickly switch between production tasks with different accuracy requirements. The embodiment of the present invention enables the twisting process to adapt to the production of flat wire products of different specifications through multiple parameter settings given by the user.

[0071] S102, obtaining a calculation result according to a plurality of setting parameters.

[0072] In the embodiment of the present invention, the calculation results obtained based on multiple setting parameters include: total stroke, over-torque cam points, end point stroke points, and mirror points; specifically, the total stroke is equal to the end point height plus the over-torque height, and the end point height is equal to the height before bending minus the height after bending; the over-torque cam points are equal to the over-torque height divided by the sampling accuracy; the end point stroke points are equal to the end point height divided by the sampling accuracy; the mirror points are equal to the end point stroke points plus the over-torque cam points.

[0073] The embodiment of the present invention provides a detailed plan for the equipment movement in the head-turning process by calculating the total stroke, the number of over-torque cam points, the number of travel points to the end point and the number of mirror points. The equipment can reasonably arrange the movement path and action sequence according to these precise values, avoid unnecessary actions and time waste, thereby optimizing the production process and improving production efficiency.

[0074] S103, inputting the calculation result into the point set formula of each layer of the twisting head mold to obtain a data set, wherein the point set formula includes a parameter equation and a compensation equation of the spatial displacement;

[0075] Specifically, the parametric equation of spatial displacement is expressed as:

[0076] Z=k*Z1*(1-cosθ)

[0077] Where Z is the height displacement; Z1 is the known bending height (which can be directly obtained by measuring the stator product); θ is the circumferential rotation angle; k = 2 / (known circumferential rotation angle*π / 180) 2 ; Known circumferential rotation angle = 360*span / number of stator slots;

[0078] Since the starting and ending points of the expanded copper wire and the twisted copper wire are not on the same circumference, the motion trajectory established according to the above parameter equation still has a slight deviation from the actual path, and the above parameter equation needs to be compensated. The compensation equation is expressed as:

[0079] Δ=Nsin(nθ)

[0080] Among them, Δ is the height compensation; n is a parameter related to the span; n=90 / known circumferential rotation angle; N is the compensation coefficient (N is a constant, generally selected between 0.5-2 according to debugging).

[0081] The path formed by the embodiment of the present invention to the terminal height is obtained by adding the calculation result of the parameter equation of spatial displacement to the calculation result of the compensation equation. Since the copper wire will rebound, in order to ensure the torsional position, it is necessary to twist and return. Therefore, the embodiment of the present invention adds the torsion height and the return path to the movement route. The return path formed by the torsion height and the return path formed by the mirror points are calculated without compensation using the parameter equation of spatial displacement.

[0082] The embodiment of the present invention determines the path formed to the terminal height by adding the calculation results of the spatial displacement parameter equation and the compensation equation, and fully considers the influence of various factors on the path. The spatial displacement parameter equation can describe the ideal motion trajectory of an object in space based on the basic kinematic principles, while the compensation equation can correct various interference factors in actual production. Such a combination method can make the path to the terminal height more accurate, which helps to improve the dimensional accuracy and shape accuracy of the product in the head twisting process, thereby ensuring product quality; the over-torque operation usually has a key impact on the final performance and shape of the product. The accurate over-torque path can ensure the processing quality of the product at this critical stage and avoid product defects caused by improper over-torque; the return path formed by the mirror point number is used as a mirror path of the over-torque path, which ensures the symmetry of the entire processing process. The symmetrical path helps to maintain the force balance of the product during the processing process and reduce the deformation caused by uneven force; on the other hand, from the perspective of the geometric shape and performance of the product, the symmetrical processing path helps to ensure the shape accuracy and internal stress distribution of the product, and further improves the product quality. By combining the spatial displacement parameter equation and the compensation equation to determine the height path to the end point, and rationally planning the over-torque path and return path, the overall motion trajectory of the equipment can be optimized. When the equipment performs the head-twisting process, it can move along the most reasonable path, avoiding unnecessary detours and pauses, thereby improving production efficiency and reducing processing time.

[0083] S104, writing the data set into a control file of a preset path, and performing a twisting process on the flat copper wire after the expansion process based on the control file.

[0084] The embodiment of the present invention ensures the accurate execution of the head twisting process based on the control file generated as a guide, thereby improving the reliability and stability of production.

[0085] The method provided in the embodiment of the present invention can obtain a motion trajectory that is basically consistent with the actual motion trajectory by adding a compensating spatial displacement parameter equation calculation, thereby avoiding scratches on the copper wire caused by relative displacement between the twisting head die and the copper wire; the product equipment process trajectory calculation and the mold change calculation can be quickly performed to adapt to the production of flat wire products of different specifications, save labor, and improve work efficiency.

[0086] In one embodiment, if Figure 3 As shown, in this embodiment, a process calculation method for a flat wire stator twisting device is provided. Figure 3 is a flow chart of a process calculation method for a flat wire stator twisting device according to an embodiment of the present invention. Figure 3 As shown, the process includes the following steps:

[0087] S201, initialize the data structure and enter the key monitoring waiting process.

[0088] The embodiment of the present invention can ensure that the system is in a known and stable initial state by initializing the data structure and entering the key monitoring waiting process, so as to facilitate the accurate execution of subsequent steps. At the same time, the key monitoring waiting process gives users the opportunity to actively participate, and users can start the subsequent process in a timely manner according to actual needs, thereby improving the flexibility and interactivity of the system.

[0089] S202, obtaining multiple setting parameters of the head twisting process input by the user.

[0090] The embodiment of the present invention allows the user to set personalized parameters according to specific process requirements and product characteristics by setting a user interaction interface, thereby ensuring that the head twisting process can meet different production needs. The specific parameters are described in the above step S101 and will not be repeated here.

[0091] S203, converting the multiple setting parameters into a calculation process according to a preset format, and clearing historical data.

[0092] The embodiment of the present invention enters the operation process by setting multiple parameters and clearing historical data, thereby ensuring the accuracy and consistency of data, avoiding the interference of historical data on current operations, and making the operation results more reliable.

[0093] S204, inputting the calculation result into the point set formula of each layer of the twisting head mold to obtain a data set, wherein the point set formula includes a parameter equation and a compensation equation of the spatial displacement.

[0094] The specific equation is described in the above step S103 and will not be repeated here. The present invention ensures the accuracy and rationality of the motion trajectory data through the compensated spatial displacement parameter equation, and provides accurate guidance for the subsequent head twisting process.

[0095] S205, based on the drawing control, the data sets of each layer are drawn into a curve for display, wherein the horizontal coordinate of the curve is the circumferential rotation angle, and the vertical coordinate is the height displacement.

[0096] The embodiment of the present invention sets the horizontal coordinate of the curve to the circumferential rotation angle and the vertical coordinate to the height displacement. This intuitive display method enables the user to clearly understand the distribution and change trend of the motion trajectory, which is convenient for the user to analyze and judge, discover problems in time and make adjustments.

[0097] Specifically, you can intuitively see the height displacement of each layer of the twisting die under the change of circumferential rotation angle, so as to better understand and grasp the details of the processing process. In terms of quality monitoring, this curve display provides a convenient basis for quality judgment. If the product has quality problems during the twisting process, such as abnormal height displacement, then the curve will show deviations from the normal curve. The curve display can be used to intuitively evaluate the effect of the process. Different process parameter settings will lead to different curve shapes. Production personnel can compare the curves of different batches of products, or observe the changes in the curve after the process is adjusted to determine whether the process adjustment has achieved the expected effect. The shape and characteristics of the curve can provide precise guidance for parameter adjustment. The parameter adjustment method based on the curve is more scientific and accurate, which helps to improve the efficiency of process optimization.

[0098] S206: Acquire a control file generation signal triggered by the user.

[0099] The embodiments of the present invention can allow the user to independently decide the timing of generating a control file after confirming that all data and parameters are accurate, and improve flexibility and interactivity by starting subsequent processes in a timely manner according to actual needs.

[0100] S207, writing the data set into a control file of a preset path, and performing a twisting process on the flat copper wire after the expansion process based on the control file.

[0101] The embodiment of the present invention performs a head twisting process on the flat copper wire after the expansion process based on a control file, thereby ensuring accurate execution of the head twisting process and improving the reliability and stability of production.

[0102] The method provided by the embodiment of the present invention has the advantages of efficient initialization, accurate parameter setting, intuitive display and user-directedness. It can avoid large relative displacement between the twisting die and the bending point of the copper wire, which may cause scratches on the copper wire. It can effectively improve the production efficiency and quality of the flat copper wire twisting process, and quickly calculate the process trajectory of the product equipment and perform the changeover calculation to adapt to the production of flat wire products of different specifications.

[0103] In a specific embodiment, the embodiment of the present invention starts to execute a predetermined task after running the program, such as Figure 4 As shown in the figure, the data is first initialized, such as related arrays, pointers, structures, etc., and then the key monitoring waiting process is entered. The user can Figure 5 The user interaction interface shown is used to input various parameters (taking the twist head die as an example with 8 layers, input the height before bending, span, compensation coefficient, sampling accuracy, number of stator slots, height after bending, and over-torque height of each layer), and then the input data will be collected and converted into a certain format to enter the calculation process: the first step is to clear the screen and clear the historical curves; the second step is to clear the variables and data; the third step is to calculate the variable values ​​of each node. The process of calculating the variable value is: the end point height plus the over-torque height is obtained to obtain the total stroke, the over-torque height is divided by the sampling accuracy to obtain the number of over-torque cam points, the end point height is divided by the sampling accuracy to obtain the number of end point stroke points, the end point stroke points plus the over-torque cam points are obtained to obtain the mirror point number, and the calculation results of the variable values ​​are respectively input into the point set formula of each layer to obtain the data set and merge the 8-layer data set into a curve through the drawing control (such as Figure 5 When the system detects that the user presses the CSV button, it writes the data set to the control file (for example, output.csv) in the specified path, and fills the data in the fields updown, 1th, 2th, ... 8th, as shown in the figure. Figure 6 As shown; finally, the flat copper wire after the expansion process is twisted based on the csv file. In actual applications, the production personnel will also adjust the input multiple setting parameters according to the actual product twisting effect to achieve a satisfactory product.

[0104] In this embodiment, a process calculation system for a flat wire stator twisting device is also provided, which is used to implement the above-mentioned embodiments and preferred implementation modes, and will not be repeated hereafter. As used below, the term "module" can be a combination of software and / or hardware that implements a predetermined function. Although the system described in the following embodiments is preferably implemented in software, the implementation of hardware, or a combination of software and hardware, is also possible and conceivable.

[0105] This embodiment provides a process calculation system for a flat wire stator twisting device, such as Figure 7 As shown, including:

[0106] The parameter setting module 701 is used to obtain multiple setting parameters of the head twisting process input by the user;

[0107] A calculation module 702, configured to calculate a calculation result according to the plurality of setting parameters;

[0108] A data set acquisition module 703 is used to input the calculation result into the point set formula of each layer of the twisting head mold to obtain a data set, wherein the point set formula includes a parameter equation and a compensation equation of the spatial displacement;

[0109] The twisting process control module 704 is used to write the data set into a control file with a preset path, and perform a twisting process on the flat copper wire after the expansion process based on the control file.

[0110] In some optional embodiments, the multiple setting parameters of the head twisting process input by the user include: the height of each layer before bending, the span, the compensation coefficient, and the sampling accuracy, the number of stator slots, the height after bending, and the over-torque height;

[0111] The calculation results include: total stroke, over-torque cam points, end stroke points, and mirror points; where:

[0112] The total stroke is equal to the height to the end point plus the twisted height, and the height to the end point is equal to the height before bending minus the height after bending;

[0113] The number of over-torque cam points is equal to the over-torque height divided by the sampling accuracy;

[0114] The number of travel points to the end point is equal to the height to the end point divided by the sampling accuracy;

[0115] The number of mirror points is equal to the number of travel points to the end point plus the number of over-torque cam points.

[0116] In some optional embodiments, the parameter equation of the spatial displacement is expressed as:

[0117] Z=k*Z1*(1-cosθ)

[0118] Where Z is the height displacement; Z1 is the known bending height; θ is the circumferential rotation angle; k = 2 / (known circumferential rotation angle*π / 180) 2 ; Known circumferential rotation angle = 360*span / number of stator slots;

[0119] The compensation equation is expressed as:

[0120] Δ=Nsin(nθ)

[0121] Wherein, Δ is the height compensation; n is a parameter related to the span, n = 90 / known circumferential rotation angle, and N is the compensation coefficient;

[0122] The path formed to the terminal height is obtained by adding the calculation result of the parameter equation of spatial displacement to the calculation result of the compensation equation, and the return path formed by the over-torque height and the return path formed by the number of mirror points are calculated by the parameter equation of spatial displacement.

[0123] In some optional embodiments, the system, such as Figure 8 As shown, it also includes: a curve trajectory display module 705, which is used to draw the data sets of each layer into a curve display based on a drawing control, where the horizontal coordinate of the curve is the circumferential rotation angle, and the vertical coordinate is the height displacement.

[0124] In some optional embodiments, the system further comprises:

[0125] Initialization module 706, used to initialize the data structure and enter the key monitoring waiting process;

[0126] The pre-processing module 707 is used to convert the plurality of setting parameters into a calculation process according to a preset format and clear the historical data;

[0127] A trigger signal acquisition module 708 is used to acquire a control file generation signal triggered by a user;

[0128] The further functional description of each of the above modules and units is the same as that of the above corresponding embodiments and will not be repeated here.

[0129] The process calculation system of the flat wire stator twisting equipment in this embodiment is presented in the form of a functional unit, where the unit refers to an ASIC (Application Specific Integrated Circuit) circuit, a processor and memory that executes one or more software or fixed programs, and / or other devices that can provide the above functions.

[0130] The embodiment of the present invention also provides a computer device having the above Figure 7 Or the process calculation system of the flat wire stator twisting equipment shown in 8.

[0131] See also Fig. 9 , Fig. 9 is a schematic diagram of the structure of a computer device provided by an optional embodiment of the present invention, such as Fig. 9As shown, the computer device includes: one or more processors 10, a memory 20, and interfaces for connecting various components, including high-speed interfaces and low-speed interfaces. Various components are connected to each other using different buses for communication, and can be installed on a common mainboard or installed in other ways as needed. The processor can process the instructions executed in the computer device, including instructions stored in or on the memory to display the graphical information of the GUI on an external input / output device (such as, a display device coupled to the interface). In some optional embodiments, if necessary, multiple processors and / or multiple buses can be used together with multiple memories and multiple memories. Similarly, multiple computer devices can be connected, and each device provides some necessary operations (for example, as a server array, a group of blade servers, or a multi-processor system). Fig. 9 A processor 10 is taken as an example.

[0132] The processor 10 may be a central processing unit, a network processor or a combination thereof. The processor 10 may further include a hardware chip. The hardware chip may be a dedicated integrated circuit, a programmable logic device or a combination thereof. The programmable logic device may be a complex programmable logic device, a field programmable gate array, a general purpose array logic or any combination thereof.

[0133] The memory 20 stores instructions executable by at least one processor 10, so that at least one processor 10 executes the method shown in the above embodiment.

[0134] The memory 20 may include a program storage area and a data storage area, wherein the program storage area may store an operating system, an application required for at least one function; the data storage area may store data created according to the use of the computer device, etc. In addition, the memory 20 may include a high-speed random access memory, and may also include a non-transient memory, such as at least one disk storage device, a flash memory device, or other non-transient solid-state storage device. In some optional embodiments, the memory 20 may optionally include a memory remotely arranged relative to the processor 10, and these remote memories may be connected to the computer device via a network. Examples of the above-mentioned network include, but are not limited to, the Internet, an intranet, a local area network, a mobile communication network, and combinations thereof.

[0135] The memory 20 may include a volatile memory, such as a random access memory; the memory may also include a non-volatile memory, such as a flash memory, a hard disk or a solid state drive; the memory 20 may also include a combination of the above types of memory.

[0136] The computer device further comprises a communication interface 30 for the computer device to communicate with other devices or a communication network.

[0137] The embodiment of the present invention also provides a computer-readable storage medium. The method according to the embodiment of the present invention can be implemented in hardware, firmware, or can be implemented as a computer code that can be recorded in a storage medium, or can be implemented as a computer code that is originally stored in a remote storage medium or a non-temporary machine-readable storage medium and will be stored in a local storage medium through a network download, so that the method described herein can be stored in such software processing on a storage medium using a general-purpose computer, a dedicated processor, or programmable or dedicated hardware. Among them, the storage medium can be a magnetic disk, an optical disk, a read-only storage memory, a random access memory, a flash memory, a hard disk or a solid-state hard disk, etc.; further, the storage medium can also include a combination of the above types of memories. It can be understood that a computer, a processor, a microprocessor central control system or programmable hardware includes a storage component that can store or receive software or computer code. When the software or computer code is accessed and executed by a computer, a processor or hardware, the method shown in the above embodiment is implemented.

[0138] A part of the present invention may be applied as a computer program product, such as a computer program instruction, which, when executed by a computer, can call or provide the method and / or technical solution according to the present invention through the operation of the computer. Those skilled in the art should understand that the existence of the computer program instruction in a computer-readable medium includes, but is not limited to, a source file, an executable file, an installation package file, etc., and accordingly, the way in which the computer program instruction is executed by the computer includes, but is not limited to: the computer directly executes the instruction, or the computer compiles the instruction and then executes the corresponding compiled program, or the computer reads and executes the instruction, or the computer reads and installs the instruction and then executes the corresponding installed program. Here, the computer-readable medium may be any available computer-readable storage medium or communication medium accessible to the computer.

[0139] The embodiment of the present invention provides a flat wire stator twisting device, such as Fig.10 As shown, it includes: a combing mechanism 1, a truss 2, a head twisting mechanism 3 and a controller ( Fig.10 ), wherein: the electric cylinder on the combing mechanism 1 can perform lifting and lowering movements; the truss 2 is provided with a motor, which controls the combing mechanism 1 to take the flat wire stator and move it to the top of the twisting mechanism 3; the twisting die 301 of the twisting mechanism 3 is multi-layered, and each layer is controlled by a controller to control the servo motor to drive the combing mechanism 1 to lower the stator to the twisting die 301 to put the stator copper wire into the die and perform the twisting process based on the control file obtained by the process calculation method of the flat wire stator twisting equipment in any of the above embodiments.

[0140] In one embodiment, the operation process of the head twisting equipment is as follows: the controller controls the motor on the truss to drive the combing mechanism to pick up the material from the double-speed chain and then move horizontally to the top of the head twisting mechanism. The combing mechanism lowers the stator to the head twisting die, and the stator copper wire enters the die. The die entry height is the height from the end of the copper wire to the bending point to start the head twisting. The control curve of the circumferential motion driven by the servo motors at each layer of the head twisting die and the axial motion of the combing electric cylinder is obtained by the calculation method mentioned above. After the head twisting is completed, the combing mechanism rises and moves horizontally down the line.

[0141] It should be noted that since the stator copper wire is multi-layered, the twisting mechanism is set to be multi-layered; each layer of the twisting mechanism is equipped with a servo motor, and there is only one combing mechanism; the servo motors and combing cylinders of each layer of the twisting mechanism move synchronously, the servo drives the twisting die to move circumferentially, and the combing cylinder moves up and down, that is, axially. The die entry height is the distance from the end of the copper wire to the bending point, which is obtained by product measurement. The path formed by the compensated spatial displacement parameter equation is determined, and the influence of various factors on the path is fully considered. The over-torque height is determined according to the debugging, and the value between 0-2mm is generally selected. Its path is determined according to the parameter equation of the uncompensated spatial displacement, and the return path is its mirror curve. When the twisting die is running, the Z variable linear increment is controlled according to the set sampling accuracy, and θ changes in real time according to Z. By changing the sampling accuracy, it can quickly switch between production tasks with different accuracy requirements.

[0142] The flat wire stator twisting equipment provided in the embodiment of the present invention can be accurately adjusted according to different process requirements and parameters through the intelligent control of the controller, ensuring the accuracy and consistency of the twisting process. Through the coordinated work of various parts, an automated, efficient and precise production process is realized, which not only improves production efficiency and reduces labor intensity, but also ensures the quality stability of the product.

[0143] Although the embodiments of the present invention have been described in conjunction with the accompanying drawings, those skilled in the art may make various modifications and variations without departing from the spirit and scope of the present invention, and such modifications and variations are all within the scope defined by the appended claims.

Claims

1. A process calculation method for a flat wire stator twisting device, characterized in that: include: Obtain multiple setting parameters of the head-turning process input by the user; Calculate and obtain a calculation result according to the multiple setting parameters; Inputting the calculation result into the point set formula of each layer of the twisting head mold to obtain a data set, wherein the point set formula includes a parameter equation and a compensation equation of the spatial displacement; The data set is written into a control file of a preset path, and a twisting process is performed on the flat copper wire after the expansion process based on the control file.

2. The method according to claim 1, characterized in that The user inputs multiple setting parameters of the head twisting process including: the height before bending, span, compensation coefficient, sampling accuracy, number of stator slots, height after bending, and over-torque height of each layer; The calculation results include: total stroke, over-torque cam points, end stroke points, and mirror points; where: The total stroke is equal to the height to the end point plus the twisted height, and the height to the end point is equal to the height before bending minus the height after bending; The number of over-torque cam points is equal to the over-torque height divided by the sampling accuracy; The number of travel points to the end point is equal to the height to the end point divided by the sampling accuracy; The number of mirror points is equal to the number of travel points to the end point plus the number of over-torque cam points.

3. The method according to claim 2, characterized in that The parametric equation of the spatial displacement is expressed as: Z=k*Z1*(1-cosθ) Where Z is the height displacement; Z1 is the known bending height; θ is the circumferential rotation angle; k = 2 / (known circumferential rotation angle*π / 180) 2 ; Known circumferential rotation angle = 360*span / number of stator slots; The compensation equation is expressed as: Δ=Nsin(nθ) Wherein, Δ is the height compensation; n is a parameter related to the span; n = 90 / known circumferential rotation angle; N is the compensation coefficient; The path formed by the end height is obtained by adding the calculation result of the parameter equation of the spatial displacement to the calculation result of the compensation equation. The over-torque path formed by the over-torque height is calculated by the parameter equation of the spatial displacement. The return path formed by the mirror point number is a mirror path of the over-torque path.

4. The method according to claim 3, characterized in that After the step of inputting the calculation result into the point set formula of each layer of the twisting head mold to obtain the data set, it also includes: drawing the data set of each layer into a curve based on a drawing control, the horizontal coordinate of the curve is the circumferential rotation angle, and the vertical coordinate is the height displacement.

5. The method according to claim 1 or 4, characterized in that: Before the step of obtaining a plurality of setting parameters of the head-turning process input by the user, the method further includes: Initialize the data structure and enter the key monitoring waiting process; After the step of obtaining a plurality of setting parameters of the head-turning process input by the user, the method further includes: The plurality of setting parameters are converted into a preset format and processed into a calculation process, and historical data is cleared; Before the step of writing the data set into the control file of the preset path, the method further includes: Gets the user-triggered control file generation signal.

6. A process calculation system for a flat wire stator twisting device, characterized in that: include: A parameter setting module, used to obtain multiple setting parameters of the head twisting process input by the user; A calculation module, used for calculating and obtaining a calculation result according to the plurality of setting parameters; A data set acquisition module, used for inputting the calculation result into the point set formula of each layer of the twisting head mold to obtain a data set, wherein the point set formula includes a parameter equation and a compensation equation of the spatial displacement; The twisting process control module is used to write the data set into a control file with a preset path, and perform a twisting process on the flat copper wire after the expansion process based on the control file.

7. A computer device, characterized in that: include: A memory and a processor, wherein the memory and the processor are communicatively connected to each other, the memory stores computer instructions, and the processor executes the process calculation method of the flat wire stator twisting device according to any one of claims 1 to 5 by executing the computer instructions.

8. A computer-readable storage medium, characterized in that: The computer-readable storage medium stores computer instructions, and the computer instructions are used to enable a computer to execute the process calculation method for the flat wire stator twisting device according to any one of claims 1-5.

9. A computer program product, characterized in that It comprises computer instructions, and the computer instructions are used to enable a computer to execute the process calculation method of the flat wire stator twisting equipment according to any one of claims 1-5.

10. A flat wire stator twisting device, characterized in that: include: Wire combing mechanism, truss, head twisting mechanism and controller, including: The electric cylinder on the thread combing mechanism can perform lifting and lowering movements; The truss is provided with a motor, and the motor is controlled by a controller to move the wire combing mechanism to take the flat wire stator and then move to the top of the twisting mechanism; The twisting die of the twisting mechanism is multi-layered, and each layer is provided with a servo motor. The controller controls the servo motor to drive the wire combing mechanism to lower the stator to the twisting die to feed the stator copper wire into the die, and performs the twisting process based on the control file obtained by the process calculation method of the flat wire stator twisting equipment described in any one of claims 1-5.

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