Continuous wave winding 2D forming equipment for manufacturing wave winding flat wire stator and control method

Abstract

The invention discloses continuous wave winding 2D forming equipment for manufacturing a wave winding flat wire stator and a control method, and relates to the technical field of new energy automobile driving wave winding flat wire motor production and manufacturing, and the continuous wave winding 2D forming equipment comprises a linear forming device, a linear conveying device, a linear supporting device and a wave winding 2D forming unit; according to the continuous wave winding 2D forming equipment for manufacturing the wave winding flat wire stator and the control method provided by the invention, a split type mold motion forming technology and a forming synchronous control technology are adopted, so that the difficult problem of a 2D forming process of an enameled wire of a new generation of flat wire motor can be effectively solved; the linear size stability after forming is improved, poor forming is reduced, the blank of the existing production technology is solved, the diversified production requirements of the driving flat wire continuous wave winding motor in the automobile manufacturing industry are met, and great influence and far-reaching significance are achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of production and manufacturing of wave-wound flat wire motors driven by new energy vehicles, and specifically to a continuous wave-wound 2D molding device and a control method for manufacturing wave-wound flat wire stators. Background Art

[0002] With the rapid development of new energy vehicles, the performance requirements for drive motors are becoming increasingly stringent. This has led to the emergence of new armature winding structures for flat-wire motors, evolving from conventional hairpin motors to the next generation of continuous-wave wound motors. Currently, the length of hairpin flat-wire stator enameled wire is typically between 600 and 800 mm, forming a U- or I-shape after forming. The forming process and equipment are relatively simple. However, the stator enameled wire for continuous-wave wound flat-wire motors is a single, continuous wire. During the forming process, uneven stress on the copper wire and high local pressure cause stretching, making it prone to breakage. A single wire, after straightening, is nearly 10 meters long, but the overall length shortens after forming, making it prone to falling, bending, and deformation during forming and transportation. The wire dimensions after forming are unstable, making it difficult to meet the requirements of subsequent wiring and inserting processes. To address the production challenges associated with the forming of the next generation of continuous-wave wound motor stator enameled wire, the market urgently needs a new long-length 2D enameled wire forming method and equipment to meet the production needs of the next generation of flat-wire continuous-wave wound motors.

[0003] A stator flat wire 2D and 3D forming device with application number: CN202310993338.0 is used to bend straight flat copper wire into hairpin-shaped 2D and 3D wire shapes, and then insert multiple hairpin coils into the slots of the stator core according to a certain arrangement to form the required single-phase motor or multi-phase motor winding. However, this winding method has the problems of too many welds, difficult to control welding quality, poor process manufacturing, and high cost of automated production; and the hairpin winding structure requires frequent twisting and welding during the winding process, and a post-weld process is also required after winding, and the cleanliness of the motor winding process cannot be guaranteed. Summary of the Invention

[0004] The purpose of the present invention is to provide a continuous wave-wound 2D forming device and control method for manufacturing wave-wound flat wire stators, so as to solve the problems raised in the above-mentioned background technology that the continuous wave-wound flat wire is easily damaged during the forming process, easily falls, bends and deforms during the forming and transportation process, and the wire size is unstable after forming, which cannot meet the requirements of subsequent wire arrangement, wire embedding and other processes.

[0005] To achieve the above object, the present invention provides the following technical solutions: A continuous wave winding 2D forming device for manufacturing a wave-wound flat wire stator, comprising a straight forming device, a straight conveying device, a straight supporting device, and a wave winding 2D forming unit arranged in sequence; the straight forming device includes an unwinding part at the leftmost side, and a forming bracket is arranged on its right side. On the top surface of the forming bracket, a steering roller, a vertical straightening roller group, a horizontal straightening roller group, and a continuous feeding part are arranged in sequence from left to right; the straight conveying device includes a conveying bracket and a conveying motor is arranged on its top surface; the straight supporting device includes a supporting bracket and a supporting guide rail transversely arranged on its top surface. A moving motor that can move along its axial direction is arranged on the supporting guide rail, and the moving motor is connected with an enameled wire spring clamping part also arranged on the supporting guide rail. On the left side of the top surface of the supporting bracket, a supporting roller group is arranged through a bracket, and on the right side, a supporting guide groove is arranged through a bracket; the wave winding 2D forming unit includes a 2D forming frame, a 2D forming device is arranged at the center of the top surface of the 2D forming frame, and a supporting frame above the 2D forming device is commonly arranged at the four corners of the top surface of the 2D forming frame. A human-machine interface is arranged at the middle of the vertical height of the front side of the supporting frame, and an alarm lamp is arranged at the top of the supporting frame.

[0006] Preferably, the top surfaces of the forming bracket, the conveying bracket, and the supporting bracket are at the same horizontal height.

[0007] Preferably, the 2D forming device includes a supporting bottom plate arranged on the 2D forming frame. On the left part of the top surface of the supporting bottom plate, two forming guide rails are transversely arranged. A left moving clamping die supporting device, a right middle die driving device, and a common connected moving clamping die driving device are commonly arranged on the two forming guide rails. At the right end of the two forming guide rails, a fixed clamping die supporting device is arranged on the top surface of the supporting bottom plate. On the right side of the fixed clamping die supporting device, an end forming device is arranged on the top surface of the supporting bottom plate. In front of the end forming device, a plurality of forming die storage positions are arranged on the top surface of the supporting bottom plate and different specifications of 2D forming dies are stored.

[0008] Preferably, the 2D forming die adopts a split design and includes a left ejector block arranged on the left side and a right ejector block arranged on the right side. Above the left ejector block, there is a left 2D forming block which is fixedly connected together by screws and pins. An I-shaped positioning groove is arranged at the bottom of the left 2D forming block, and a continuous-wave winding profiling groove is arranged on the surface of the left 2D forming block. Above the right ejector block, there is a right 2D forming block which is fixedly connected together by screws and pins. An I-shaped positioning groove is arranged at the bottom of the right 2D forming block, and a continuous-wave winding profiling groove is arranged on the surface of the right 2D forming block. Above the left 2D forming block and the right 2D forming block, there is a 2D forming pressing block. A quick-change handle is arranged on the top surface of the 2D forming pressing block, and a quick-change pin is arranged on the front vertical surface. A rectangular groove is arranged at the base of the 2D forming pressing block. The left 2D forming block is a movable die installed on a movable clamping die support device and driven by a movable clamping die driving device. The right 2D forming block is a fixed die installed on a fixed clamping die support device.

[0009] Preferably, the movable clamping die support device includes a movable guide rail seat arranged at the bottom on two forming guide rails. A movable flat plate is arranged on the top surface of the movable guide rail seat. A movable support block is arranged on the top surface of the movable flat plate. A movable support plate is arranged on the top surface of the movable support block. A movable die quick-change seat is arranged on the top surface of the movable support plate. A pressing handle A is arranged on the left side and a pressing handle B is arranged on the right side on the top surface of the movable die quick-change seat. An I-shaped groove is arranged on the movable die quick-change seat and is quickly connected to the I-shaped groove of the left 2D forming block. A positioning hole is arranged on the movable support plate and is connected to the intermediate die driving device through a driving connecting rod.

[0010] Preferably, the intermediate die driving device includes transverse movement guide rail sliders arranged on two forming guide rails. A lower support plate is jointly supported by the transverse movement guide rail sliders. A vertical plate is arranged at the side of the lower support plate. An upper support plate is jointly arranged at the top of the vertical plate. Two parallel guiding slide rails are longitudinally arranged on the top surface of the upper support plate. Driving guide rail sliders are arranged on both guiding slide rails. A connecting seat is jointly arranged on the top surfaces of the two driving guide rail sliders. A quick-change block is arranged on the top surface of the connecting seat and is used for quickly installing the 2D forming pressing block. The connecting seat is connected to a longitudinally arranged driving lead screw, and a driving motor is arranged at the rear end of the driving lead screw. Longitudinal strip-shaped limiting holes are arranged above the two forming guide rails on the lower support plate and the upper support plate, and bearings are embedded in the strip-shaped limiting holes, and a vertical rotating shaft is jointly arranged through the bearings. The rotating shaft is connected to the driving connecting rod, and the driving connecting rod is connected to the movable clamping die driving device and the fixed clamping die support device.

[0011] Preferably, the movable clamping die driving device includes fixed support blocks arranged on the top surface of the support base plate near the left and right ends between the two forming guide rails. A transverse movement lead screw is commonly arranged between the two fixed support blocks. The right end of the transverse movement lead screw is connected to a transverse movement servo motor. At the same time, a transverse movement lead screw slider is arranged on the transverse movement lead screw. The transverse movement lead screw slider is fixedly connected to the bottom surface of the movable guide rail seat. A transverse movement guide rail slider is also arranged on the bottom surface of the movable guide rail seat. The transverse movement guide rail slider is placed on the two forming guide rails.

[0012] Preferably, the fixed clamping die support device includes a fixed block arranged on the support base plate. A fixed flat plate is arranged on the top surface of the fixed block. A fixed support block is arranged on the top surface of the fixed flat plate. A fixed support plate is arranged on the top surface of the fixed support block. A fixed die quick-change seat and a fixed handle are arranged on the top surface of the fixed support plate. The enameled wire is pressed in place through the fixed handle to prevent the wire from deforming and moving during the bending process. An I-shaped groove is arranged on the fixed die quick-change seat and is quickly connected to the I-shaped groove of the right 2D forming block.

[0013] Preferably, the end forming device includes a front end forming die, a rear end forming die, and a forming die support. The front end forming die and the rear end forming die are fixed on the forming die support. The front end forming die includes a left fixed jaw, a left intermediate die block, a left forming block, and a left guide rail slider. The left fixed jaw and the left forming block are fixed on the forming die support. The left intermediate die block is fixed on the forming die support through the left guide rail slider. After the front end of the enameled wire reaches the position, the left fixed jaw fixes and clamps the enameled wire, and the left intermediate die block is manually pushed to drive the enameled wire to bend and form. The rear end forming die includes a right fixed jaw, a right intermediate die block, a right forming block, and a right guide rail slider. The right fixed jaw and the right forming block are fixed on the forming die support. The right intermediate die block is fixed on the forming die support through the right guide rail slider. After the front and rear ends of the enameled wire reach the position, the right fixed jaw fixes and clamps the enameled wire, and the right intermediate die block is manually pushed to drive the enameled wire to bend and form.

[0014] A control method for a 2D forming device for continuously wave-winding a wave-wound flat wire stator is adopted. The specific process includes:

[0015] S1 The enameled wire is straightened and fed to the position through the straight forming device, the straight conveying device, and the straight support device.

[0016] S2 The end of the enameled wire is positioned and clamped.

[0017] S3 The intermediate die driving device pushes against the enameled wire to move forward.

[0018] S4 The movable clamping die support device moves along with the intermediate die driving device, showing a linear proportional synchronous relationship.

[0019] The S5 linear conveying device moves following the movement of the movable clamping die support device, forming an equal-proportion synchronous relationship;

[0020] S6 The wave winds around the 2D forming unit until the forming is in place, and the equipment resets.

[0021] Compared with the prior art, the beneficial effects of the present invention are:

[0022] The equipment and control method for manufacturing the continuous wave winding 2D forming of the wave-wound flat wire stator provided by the present invention adopt the split die motion forming technology and the forming synchronous control technology. The equipment for manufacturing the continuous wave winding 2D forming of the wave-wound flat wire stator can effectively solve the problems in the manufacturing of the 2D forming process of the enameled wire of the new generation flat wire motor, improve the dimensional stability of the wire type after forming, reduce the forming defects, solve the blank of the existing production technology, and meet the diversified production requirements of the drive flat wire continuous wave winding motors in the automotive manufacturing industry, having great influence and far-reaching significance. Brief Description of the Drawings

[0023] Figure 1 It is the front view of the present invention;

[0024] Figure 2 It is Figure 1 the structural schematic diagram;

[0025] Figure 3 It is the axonometric view of the wave winding 2D forming unit;

[0026] Figure 4 It is the top view of the forming part of the wave winding 2D forming unit;

[0027] Figure 5 It is Figure 4 the sectional view taken along the line B-B in

[0028] Figure 6 It is the sectional view of the movable clamping die driving device;

[0029] Figure 7 It is the front view of the movable clamping die support device;

[0030] Figure 8 It is the front view of the movable clamping die driving device;

[0031] Figure 9 The top view of the end forming;

[0032] Figure 10 It is the top view of the 2D forming die;

[0033] Figure 11 It is the schematic diagram of the positions of the moving parts after forming;

[0034] Figure 12 It is the schematic diagram of the forming process of the enameled wire of the wave-wound flat wire stator;

[0035] Figure 13 Schematic diagram of the rear end of the enameled wire of the wave-wound flat wire stator after forming;

[0036] Figure 14 Schematic diagram of the front end of the enameled wire of the wave-wound flat wire stator after forming;

[0037] In the figure: straight forming device - 1, unwinding part - 11, forming bracket - 12, turning roller - 13, vertical straightening roller group - 14, horizontal straightening roller group - 15, continuous feeding part - 16, straight conveying device - 2, conveying bracket - 21, conveying motor - 22, straight supporting device - 3, supporting bracket - 31, supporting guide rail - 32, moving motor - 33, enameled wire spring clamping part - 34, supporting roller group - 35, supporting guide groove - 36, wave-wound 2D forming unit - 4, 2D forming frame - 41, 2D forming device - 42, supporting bottom plate - 421, forming guide rail - 422, moving clamping die supporting device - 423, moving guide rail seat - 4231, moving flat plate - 4232, moving support block - 4233, moving support plate - 4234, moving die quick-change seat - 4235, pressing handle A - 4236, pressing handle B - 4237, driving connecting rod - 4238, intermediate die driving device - 424, lower support plate - 4241, vertical plate - 4242, upper support plate - 4243, guiding slide rail - 4244, driving guide rail slider - 4245, connecting seat - 4246, quick-change block - 4247, driving lead screw - 4248, driving motor - 4249, rotating shaft - 4240, moving clamping die driving device - 425, fixed support block - 4251, transverse movement lead screw - 4252, transverse movement servo motor - 4253, transverse movement lead screw slider - 4254, transverse movement guide rail slider - 4255, fixed clamping die supporting device - 426, fixed block - 4261, fixed flat plate - 4262, fixed support block - 4263, fixed support plate - 4264, fixed die quick-change seat - 4265, fixed handle - 4266, end forming device - 427, left fixed jaw - 4271, left intermediate die block - 4272, left forming block - 4273, left guide rail slider - 4274, right fixed jaw - 4275, right intermediate die block - 4276, right forming block - 4277, right guide rail slider - 4278, 2D forming die - 428, left top block - 4281, right top block - 4282, left 2D forming block - 4283, right 2D forming block - 4284, 2D forming pressing block - 4285, quick-change handle - 4286, quick-change pin - 4287, support frame - 43, human-machine interface - 44, alarm lamp - 45. Specific implementation method

[0038] To enable those skilled in the art to better understand the technical solution of the present invention, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings and specific embodiments.

[0039] Please refer to Figure 1-14 , Figure 1 which is the front view of the present invention; Figure 2 is Figure 1 the structural schematic diagram; Figure 3 is the axonometric view of the wave-wound 2D forming unit; Figure 4 is the top view of the forming part of the wave-wound 2D forming unit; Figure 5 is Figure 4 the sectional view taken along line B-B in Figure 6 is the sectional view of the moving clamping die driving device; Figure 7 is the front view of the moving clamping die supporting device; Figure 8 is the front view of the moving clamping die driving device; Figure 9 is the top view of the end forming; Figure 10 is the top view of the 2D forming die; Figure 11 is the schematic diagram of the position of the moving parts after forming;

[0040] Figure 12 is the schematic diagram of the forming process of the wave-wound rectangular wire stator enameled wire; Figure 13 is the rear end schematic diagram of the wave-wound rectangular wire stator enameled wire after forming; Figure 14 is the front end schematic diagram of the wave-wound rectangular wire stator enameled wire after forming.

[0041] The present invention provides a continuous wave-wound 2D forming device for manufacturing a wave-wound rectangular wire stator, which is used to continuously bend an enameled wire with a straightened single length of nearly 10 meters into a continuous wave-wound 2D enameled wire with a length of nearly 3 meters, so as to complete the 2D bending forming operation of the longer enameled wire, thereby meeting the production requirements of the new generation of motors with rectangular wire continuous wave winding; it includes a straight forming device 1, a straight conveying device 2, a straight supporting device 3, and a wave-wound 2D forming unit 4 arranged in sequence according to the forming process of the enameled wire; among them, the straight forming device 1, the straight conveying device 2, and the straight supporting device 3 cooperate to complete the straightening and conveying operation of the 10m enameled wire, and the wave-wound 2D forming unit 4 is used to continuously bend the 10-meter enameled wire into a wave-wound 2D enameled wire with a length of nearly 3 meters.

[0042] The straight wire forming device 1 includes a wire unwinding part 11 arranged at the leftmost side for unwinding the coiled enameled wire. On the right side of the wire unwinding part 11, there are jointly arranged, from left to right, a turning roller 13 for turning the unwound enameled wire, a vertical straightening roller group 14 for straightening the turned enameled wire in the vertical direction, a horizontal straightening roller group 15 for straightening the vertically straightened enameled wire in the horizontal direction, and a continuous feeding part 16 for continuously feeding the straightened enameled wire. Through the coordinated use of the wire unwinding part 11, the turning roller 13, the vertical straightening roller group 14, the horizontal straightening roller group 15, and the continuous feeding part 16, the coiled enameled wire is unwound and straightened into a long straight enameled wire; the straightened enameled wire directly enters the straight wire conveying device 2.

[0043] The straight wire conveying device 2 includes a conveying support 21 having the same height as the forming support 12. On the top surface of the conveying support 21, a conveying motor 22 is arranged through a support, and the conveying motor 22 provides power for the forward conveying of the enameled wire.

[0044] The straight wire supporting device 3 includes a supporting support 31 having the same height as the forming support 12. On the top surface of the supporting support 31, a supporting guide rail 32 is transversely arranged, and a moving motor 33 that can move along its axial direction is arranged on the supporting guide rail 32. The moving motor 33 is connected to an enameled wire spring clamping part 34 also arranged on the supporting guide rail 32, which is used to clamp the enameled wire to be conveyed and convey it to the right. At the same time, a supporting roller group 35 is arranged on the left side of the top surface of the supporting support 31 through a support, and a supporting guide groove 36 is arranged on the right side through a support, so as to assist in conveying the enameled wire to the wave winding 2D forming unit 4.

[0045] The wave winding 2D forming unit 4 includes a 2D forming frame 41. At the center of the top surface of the 2D forming frame 41, a 2D forming device 42 for performing 2D bending forming on the already straightened enameled wire is arranged. At the four corners of the top surface of the 2D forming frame 41, a supporting frame 43 is jointly arranged above the 2D forming device 42. On the front side of the supporting frame 43, a human-machine interface 44 is arranged at the middle of its vertical height. An alarm lamp 45 is arranged at the top of the supporting frame 43, which is used to perform sound and light alarms in real time to remind the staff to deal with it in time when a fault occurs.

[0046] The 2D forming device 42 includes a support bottom plate 421 disposed on the 2D forming frame 41. On the left side of the top surface of the support bottom plate 421, two forming guide rails 422 are horizontally arranged. A moving clamping die support device 423 on the left side and an intermediate die driving device 424 on the right side are jointly arranged on the two forming guide rails 422. Meanwhile, a moving clamping die driving device 425 is arranged on the support bottom plate 421 near the left end between the two forming guide rails 422. The moving clamping die driving device 425 is connected to the moving clamping die support device 423 and drives it to move axially along the two forming guide rails 422. At the right end of the two forming guide rails 422, a fixed clamping die support device 426 is arranged on the top surface of the support bottom plate 421. On the right side of the fixed clamping die support device 426, an end forming device 427 is arranged on the top surface of the support bottom plate 421. In the front side of the end forming device 427, a plurality of forming die storage positions are arranged on the top surface of the support bottom plate 421 for storing 2D forming dies 428 of different specifications.

[0047] The 2D forming die 428 adopts a split design, including a left top block 4281 arranged on the left side and a right top block 4282 arranged on the right side. Above the left top block 4281, a left 2D forming block 4283 is arranged and fixedly connected together by screws and pins. An I-shaped positioning groove is arranged at the bottom of the left 2D forming block 4286 to realize quick changeover positioning of the continuous wave winding die. A continuous wave winding profiling groove is arranged on the surface of the left 2D forming block 4283 to position the continuous wave winding after forming; above the right top block 4282, a right 2D forming block 4284 is arranged and fixedly connected together by screws and pins. An I-shaped positioning groove is arranged at the bottom of the right 2D forming block 4284 to realize quick changeover positioning of the continuous wave winding die. A continuous wave winding profiling groove is arranged on the surface of the right 2D forming block 4284 to position the continuous wave winding after forming; above the left 2D forming block 4283 and the right 2D forming block 4284, a 2D forming pressing block 4285 is jointly arranged. A quick change handle 4286 is arranged on the top surface of the 2D forming pressing block 4285, and a quick change pin 4287 is arranged on the front vertical surface. A rectangular groove is arranged at the base of the 2D forming pressing block 4285 to realize quick disassembly and assembly for easy changeover; the left 2D forming block 4283 is a moving die installed on the moving clamping die support device 423 and driven by the moving clamping die driving device 425, and the right 2D forming block 4283 is a fixed die installed on the fixed clamping die support device 426; during the 2D forming of the enameled wire, the left 2D forming block 4283 and the 2D forming pressing block 4285 are synchronously linked. The moving clamping die support device 423 moves along with the intermediate die driving device 424, forming a linear proportional synchronous relationship. The linear conveying device 2 moves along with the moving clamping die support device 423, forming an equal proportional synchronous relationship, thereby controlling the forming of the wave winding.

[0048] The movable clamping die support device 423 includes a movable guide rail base 4231 with its bottom disposed on the two forming guide rails 422. A movable flat plate 4232 is provided on the top surface of the movable guide rail base 4231. A movable support block 4233 is provided on the top surface of the movable flat plate 4232. A movable support plate 4234 is provided on the top surface of the movable support block 4233. A movable die quick-change base 4235 is provided on the top surface of the movable support plate 4234. A pressing handle A 4236 is provided on the left side and a pressing handle B 4237 is provided on the right side on the top surface of the movable die quick-change base 4235. The movable die quick-change base 4235 is provided with a T-shaped groove for quick connection with the T-shaped groove of the left 2D forming block 4283. The pressing handle A 4236 and the pressing handle B 4237 cooperate to press the enameled wire in place to prevent the wire from deforming and moving during the bending process. Positioning holes are provided on the movable support plate 4234 and it is connected to the intermediate die driving device 424 through a driving connecting rod 4238 to realize the linkage between the movable clamping die support device 423 and the intermediate die driving device 424.

[0049] The intermediate die driving device 424 includes transverse movement guide rail sliders 4255 disposed on the two forming guide rails 422. A lower support plate 4241 is commonly supported by the transverse movement guide rail sliders 4255. A vertical plate 4242 is provided at the side of the lower support plate 4241. An upper support plate 4243 is commonly provided at the top end of the vertical plate 4242. Two mutually parallel guiding slide rails 4244 are longitudinally provided on the top surface of the upper support plate 4243. Driving guide rail sliders 4245 are provided on both of the guiding slide rails 4244. A connecting seat 4246 is commonly provided on the top surfaces of the two driving guide rail sliders 4245. A quick-change block 4247 is provided on the top surface of the connecting seat 4246, and the quick-change block 4247 is used for quickly installing the 2D forming pressing block 4285. The connecting seat 4246 is connected to a longitudinally disposed driving lead screw 4248, and a driving motor 4249 is provided at the rear end of the driving lead screw 4248. In addition, the lower support plate 4241, the vertical plate 4242 and the upper support plate 4243 are fixedly connected to form a movement space. Longitudinal strip-shaped limiting holes are provided above the two forming guide rails 422 on the lower support plate 4241 and the upper support plate 4243, and bearings are embedded in the strip-shaped limiting holes, and a vertical rotating shaft 4240 is commonly provided through the bearings. The rotating shaft 4240 is connected to the driving connecting rod 4238, and the driving connecting rod 4238 is connected to the movable clamping die driving device 425 and the fixed clamping die support device 426 to realize the linkage among the intermediate die driving device 424, the movable clamping die driving device 425 and the fixed clamping die support device 426, ensuring that the intermediate die driving device 424 is always located between the movable clamping die driving device 425 and the fixed clamping die support device 426 for synchronous control of the forming time.

[0050] The mobile clamping die driving device 425 includes fixed support blocks 4251 arranged on the top surface of the support base plate 421 near the left and right ends between the two forming guide rails 422. A transverse translation lead screw 4252 is arranged between the two fixed support blocks 4251. The right end of the transverse translation lead screw 4252 is connected with a transverse translation servo motor 4253. At the same time, a transverse translation lead screw slider 4254 is arranged on the transverse translation lead screw 4252. The transverse translation lead screw slider 4254 is fixedly connected to the bottom surface of the moving guide rail seat 4231. In addition, a transverse translation guide rail slider 4255 is arranged on the bottom surface of the moving guide rail seat 4231. The transverse translation guide rail slider 4255 is placed on the two forming guide rails 422, so that the mobile clamping die support device 423 can be driven to move by the transverse translation servo motor 4253.

[0051] The fixed clamping die support device 426 includes a fixed block 4261 arranged on the support base plate 421. A fixed flat plate 4262 is arranged on the top surface of the fixed block 4261. A fixed support block 4263 is arranged on the top surface of the fixed flat plate 4262. A fixed support plate 4264 is arranged on the top surface of the fixed support block 4263. A fixed die quick change seat 4265 and a fixed handle 4266 are arranged on the top surface of the fixed support plate 4264. The enameled wire is tightly pressed in place by the fixed handle 4266 to prevent the wire from deforming and moving during the bending process. An I-shaped groove is arranged on the fixed die quick change seat 4265 and is quickly connected to the I-shaped groove of the right 2D forming block 4284.

[0052] The end forming device 427 includes a front end forming die, a rear end forming die and a forming die support. The front end forming die and the rear end forming die are fixed on the forming die support. The front end forming die includes a left fixed jaw 4271, a left intermediate die block 4272, a left forming block 4273 and a left guide rail slider 4274. The left fixed jaw 4271 and the left forming block 4273 are fixed on the forming die support. The left intermediate die block 4272 is fixed on the forming die support through the left guide rail slider 4274. After the front end of the enameled wire is in place, the left fixed jaw 4271 fixedly clamps the enameled wire, and the left intermediate die block 4272 is manually pushed to drive the enameled wire to be bent and formed. Further, it can be replaced by an automatic cylinder control instead of manual operation to achieve automation.

[0053] The described rear-end forming die includes a right fixed jaw 4275, a right intermediate die block 4276, a right forming block 4277, and a right guide rail slider 4278. The right fixed jaw 4275 and the right forming block 4277 are fixed on the forming die bracket, and the right intermediate die block 4276 is fixed on the forming die bracket through the right guide rail slider 4278. After the front and rear ends of the enameled wire are in place, the right fixed jaw 4275 fixes and clamps the enameled wire, and the operator pushes the right intermediate die block 4276 to drive the enameled wire to bend and form. Further, it can be replaced by an automatic cylinder control instead of manual operation to achieve automation.

[0054] The control method for performing 2D bending on the straightened enameled wire by using the above-mentioned continuous wave winding 2D forming equipment for manufacturing a wave-wound flat wire stator specifically includes the following processes:

[0055] S1 The enameled wire is straightened and fed to the in-place position.

[0056] S2 The end of the enameled wire is positioned and clamped.

[0057] S3 The intermediate die abuts against the enameled wire and advances.

[0058] S4 The moving clamping die servo-follows the movement of the intermediate die and has a linear proportional synchronous relationship.

[0059] S5 The straightening and feeding servo-follows the movement of the moving clamping die and has an equal proportional synchronous relationship.

[0060] S6 The continuous wave winding 2D forming is in place, and the equipment resets.

[0061] The equipment and control method for manufacturing a wave-wound flat wire stator continuous wave winding 2D forming provided by the present invention adopt a split die motion forming technology and a forming synchronous control technology. The equipment for manufacturing a wave-wound flat wire stator continuous wave winding 2D forming can effectively solve the problems in the 2D forming process of the enameled wire for the new generation of flat wire motors, improve the dimensional stability of the wire shape after forming, reduce forming defects, solve the blank of the existing production technology, and meet the diversified production requirements of the drive flat wire continuous wave winding motors in the automotive manufacturing industry, having great influence and far-reaching significance.

[0062] Although the embodiments of the present invention have been shown and described, obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, for those of ordinary skill in the art, it can be understood that without departing from the principles and spirit of the present invention, all other embodiments obtained by making various changes, modifications, substitutions, and variations to these embodiments without creative efforts belong to the scope of protection of the present invention.

Claims

1. A continuous wave winding 2D forming device for manufacturing a wave wound flat wire stator, characterized in that: It includes a straight-line forming device (1), a straight-line conveying device (2), a straight-line supporting device (3), and a wave-winding 2D forming unit (4) arranged in sequence; the straight-line forming device (1) includes an unwinding part (11) at the leftmost side, and a forming bracket (12) is arranged on its right side. On the top surface of the forming bracket (12), a turning roller (13), a vertical straightening roller group (14), a horizontal straightening roller group (15), and a continuous feeding part (16) are arranged in sequence from left to right; the straight-line conveying device (2) includes a conveying bracket (21) and a conveying motor (22) is arranged on its top surface; the straight-line supporting device (3) includes a supporting bracket (31) and a supporting guide rail (32) horizontally arranged on its top surface. A moving motor (33) that can move along its axial direction is arranged on the supporting guide rail (32), and the moving motor (33) is connected with an enameled wire spring clamping part (34) also arranged on the supporting guide rail (32). On the left side of the top surface of the supporting bracket (31), a supporting roller group (35) is arranged through a bracket, and a supporting guide groove (36) is arranged through a bracket on the right side; the wave-winding 2D forming unit (4) includes a 2D forming frame (41), a 2D forming device (42) is arranged at the center of the top surface of the 2D forming frame (41), and a supporting frame (43) above the 2D forming device (42) is commonly arranged at the four corners of the top surface of the 2D forming frame (41). A human-machine interface (44) is arranged at the middle of the vertical height of the front side of the supporting frame (43), and an alarm lamp (45) is arranged at the top of the supporting frame (43).

2. The continuous wave winding 2D forming equipment for manufacturing a wave wound flat wire stator according to claim 1, characterized in that: The top surfaces of the forming bracket (12), the conveying bracket (21), and the supporting bracket (31) are at the same horizontal height.

3. The continuous wave winding 2D forming device for manufacturing a wave wound flat wire stator according to claim 2, wherein: The 2D forming device (42) includes a supporting bottom plate (421) arranged on the 2D forming frame (41). On the left part of the top surface of the supporting bottom plate (421), two forming guide rails (422) are horizontally arranged. A left moving clamping die supporting device (423), a right middle die driving device (424), and a connected moving clamping die driving device (425) are commonly arranged on the two forming guide rails (422). At the right end of the two forming guide rails (422), a fixed clamping die supporting device (426) is arranged on the top surface of the supporting bottom plate (421). On the right side of the fixed clamping die supporting device (426), an end forming device (427) is arranged on the top surface of the supporting bottom plate (421). On the front side of the end forming device (427), a plurality of forming die storage positions are arranged on the top surface of the supporting bottom plate (421) and different specifications of 2D forming dies (428) are stored.

4. The continuous wave winding 2D forming equipment for manufacturing a wave wound flat wire stator according to claim 3, wherein: The 2D forming die (428) adopts a split design and includes a left ejector block (4281) arranged on the left side and a right ejector block (4282) arranged on the right side. Above the left ejector block (4281), a left 2D forming block (4283) is arranged and fixedly connected together by screws and pins. An I-shaped positioning groove is arranged at the bottom of the left 2D forming block (4286). A continuous wave winding profiling groove is arranged on the surface of the left 2D forming block (4283). Above the right ejector block (4282), a right 2D forming block (4284) is arranged and fixedly connected together by screws and pins. An I-shaped positioning groove is arranged at the bottom of the right 2D forming block (4284). A continuous wave winding profiling groove is arranged on the surface of the right 2D forming block (4284). Above the left 2D forming block (4283) and the right 2D forming block (4284), a 2D forming pressure block (4285) is jointly arranged. A quick-change handle (4286) is arranged on the top surface of the 2D forming pressure block (4285), and a quick-change pin (4287) is arranged on the front vertical surface. A rectangular groove is arranged at the base of the 2D forming pressure block (4285). The left 2D forming block (4283) is a movable die installed on a movable clamping die support device (423) and driven by a movable clamping die driving device (425). The right 2D forming block (4283) is a fixed die installed on a fixed clamping die support device (426).

5. The continuous wave winding 2D forming device for manufacturing a wave wound flat wire stator according to claim 4, wherein: The movable clamping die support device (423) includes a movable guide rail seat (4231) with its bottom arranged on two forming guide rails (422). A movable flat plate (4232) is arranged on the top surface of the movable guide rail seat (4231). A movable support block (4233) is arranged on the top surface of the movable flat plate (4232). A movable support plate (4234) is arranged on the top surface of the movable support block (4233). A movable die quick-change seat (4235) is arranged on the top surface of the movable support plate (4234). A pressing handle A (4236) on the left side and a pressing handle B (4237) on the right side are arranged on the top surface of the movable die quick-change seat (4235). An I-shaped groove is arranged on the movable die quick-change seat (4235) and is quickly connected to the I-shaped groove of the left 2D forming block (4283). Positioning holes are arranged on the movable support plate (4234) and are connected to the intermediate die driving device (424) through a driving connecting rod (4238).

6. The continuous wave winding 2D forming device for manufacturing a wave wound flat wire stator according to claim 5, characterized in that: The intermediate die driving device (424) includes a transverse guide rail slider (4255) arranged on two forming guide rails (422). The transverse guide rail sliders (4255) jointly support and are provided with a lower support plate (4241). A vertical plate (4242) is arranged at the side of the lower support plate (4241). The upper ends of the vertical plates (4242) jointly set an upper support plate (4243). Two mutually parallel guiding slide rails (4244) are longitudinally arranged on the top surface of the upper support plate (4243). Driving guide rail sliders (4245) are arranged on both guiding slide rails (4244). A connecting seat (4246) is jointly arranged on the top surfaces of the two driving guide rail sliders (4245). A quick-change block (4247) is arranged on the top surface of the connecting seat (4246). The quick-change block (4247) is used for quickly installing the 2D forming pressing block (4285). The connecting seat (4246) is connected with a longitudinally arranged driving lead screw (4248). A driving motor (4249) is arranged at the rear end of the driving lead screw (4248). The lower support plate (4241) and the upper support plate (4243) are provided with longitudinal strip-shaped limiting holes above the two forming guide rails (422). Bearings are embedded in the strip-shaped limiting holes, and a vertical rotating shaft (4240) is jointly arranged through the bearings. The rotating shaft (4240) is connected with the driving connecting rod (4238). The driving connecting rod (4238) is connected with the moving clamping die driving device (425) and the fixed clamping die supporting device (426).

7. The continuous wave winding 2D forming device for manufacturing a wave wound flat wire stator according to claim 6, wherein: The moving clamping die driving device (425) includes fixed support blocks (4251) arranged on the top surface of the support bottom plate (421) near the left and right ends between the two forming guide rails (422). A transverse lead screw (4252) is jointly arranged between the two fixed support blocks (4251). The right end of the transverse lead screw (4252) is connected with a transverse servo motor (4253). At the same time, a transverse lead screw slider (4254) is also arranged on the transverse lead screw (4252). The transverse lead screw slider (4254) is fixedly connected to the bottom surface of the moving guide rail seat (4231). A transverse guide rail slider (4255) is also arranged on the bottom surface of the moving guide rail seat (4231). The transverse guide rail slider (4255) is placed on the two forming guide rails (422).

8. The continuous wave winding 2D forming device for manufacturing a wave wound flat wire stator according to claim 7, characterized in that: The fixed clamping die support device (426) includes a fixed block (4261) disposed on the support base plate (421). A fixed flat plate (4262) is provided on the top surface of the fixed block (4261). A fixed support block (4263) is provided on the top surface of the fixed flat plate (4262). A fixed support plate (4264) is provided on the top surface of the fixed support block (4263). A fixed die quick-change seat (4265) and a fixed handle (4266) are provided on the top surface of the fixed support plate (4264). The enameled wire is pressed in place by the fixed handle (4266) to prevent the wire from deforming and moving during the bending process. An I-shaped groove is provided on the fixed die quick-change seat (4265) for quick connection with the I-shaped groove of the right 2D forming block (4284).

9. The continuous wave winding 2D forming device for manufacturing a wave wound flat wire stator according to claim 8, wherein: The end forming device (427) includes a front end forming die, a rear end forming die, and a forming die support. The front end forming die and the rear end forming die are fixed on the forming die support. The front end forming die includes a left fixed jaw (4271), a left intermediate die block (4272), a left forming block (4273), and a left guide rail slider (4274). The left fixed jaw (4271) and the left forming block (4273) are fixed on the forming die support. The left intermediate die block (4272) is fixed on the forming die support through the left guide rail slider (4274). After the front end of the enameled wire is in place, the left fixed jaw (4271) fixes and clamps the enameled wire, and the left intermediate die block (4272) is manually pushed to drive the enameled wire to bend and form. The rear end forming die includes a right fixed jaw (4275), a right intermediate die block (4276), a right forming block (4277), and a right guide rail slider (4278). The right fixed jaw (4275) and the right forming block (4277) are fixed on the forming die support. The right intermediate die block (4276) is fixed on the forming die support through the right guide rail slider (4278). After the rear front end of the enameled wire is in place, the right fixed jaw (4275) fixes and clamps the enameled wire, and the right intermediate die block (4276) is manually pushed to drive the enameled wire to bend and form.

10. The control method for the continuous wave winding 2D forming equipment for manufacturing a wave wound flat wire stator according to claim 1, wherein: The specific process includes: S1 The enameled wire is straightened and fed in place through the straight forming device (1), the straight conveying device (2), and the straight support device (3). S2 The end of the enameled wire is positioned and clamped. S3 The intermediate die driving device (424) pushes against the enameled wire to move forward. S4 The moving clamping die support device (423) moves along with the intermediate die driving device (424) in a linear proportional synchronous relationship. S5 The straight conveying device (2) moves along with the moving clamping die support device (423) in an equal proportional synchronous relationship. S6 The wave winding 2D forming unit (4) forms in place, and the equipment resets.

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