Universal motor hairpin winding forming tool structure

Abstract

The invention belongs to the technical field of small and medium-sized motor manufacturing, and relates to a universal motor hairpin winding forming tool structure. Comprising a narrow-edge cushion block, a hexagon socket cap screw, a narrow-edge gasket, a wide-edge gasket, a wide-edge cushion block, a handle knob, a guide rail, a base, an arc-shaped die, a hexagon nut, a front-end fixing block, a front-end mandrel, a rear-end mandrel, a rear-end fixing block and a sunk screw. Before forming, the winding wire is bent into a U shape. And the two narrow-edge cushion blocks are respectively arranged together with the base and the wide-edge cushion block to form two wire slots. The two bent edges of the winding wire are arranged in the wire grooves respectively, and the winding wire is fastened and clamped by the screws. When the handle knob is pulled, the winding wire part clamped by the wide-edge cushion block is driven by the guide rail to rotate by taking the mandrel on the base as the circle center and taking the distance between the mandrel and the wide-edge cushion block as the radius. The structure has good universality. Winding wires of different specifications can be formed, the bending radius of the winding wires can be adjusted, the rotating angle of the guide rail can be freely adjusted, and therefore the bending radian and span of the winding wires can be adjusted.

Description

Technical Field

[0001] This invention belongs to the field of small and medium-sized motor manufacturing technology, and relates to a general motor hairpin winding forming tooling structure, which is applicable to the forming of enameled wire of a certain range of specifications. It enables rapid forming of hairpin windings while allowing convenient adjustment of parameters such as curvature, radius, and span, and has strong versatility. Background Technology

[0002] Currently, permanent magnet synchronous motors using hairpin windings are increasingly used due to their high slot fill factor and high power density. For hairpin windings of specific specifications and shapes, their forming requires specialized tooling and equipment. Currently, the industry uses large-scale equipment with multiple mechanisms to form hairpin windings, such as CN113441649A (a copper wire forming device and process for hairpin motors) and CN118616609A (a flat wire forming device). These devices first bend the flat wire, then place it into a forming mold and extrude it into a preset 3D shape. However, these forming devices have poor versatility. If the winding wire size or specifications are changed, entirely new bending and forming molds need to be designed and manufactured, and the molds on the equipment also need to be replaced, which is time-consuming, labor-intensive, and affects production efficiency. Summary of the Invention

[0003] The purpose of this invention is:

[0004] The purpose of this invention is to design a universal hairpin winding forming fixture structure for motors, in which parameters such as enameled wire specifications, forming arc, radius, and span can be adjusted, thereby enabling rapid forming of various motor hairpin windings. This invention is suitable for the forming and manufacturing of hairpin windings during the motor R&D and trial production stage.

[0005] The technical solution of the present invention is as follows: a general motor hairpin winding forming fixture structure, including two narrow-side pads 1, hexagonal head screws 2, wide-side pads 5, grippers 6, two guide rails 7, a base 8, an arc-shaped mold 9, a hexagonal nut 10, a front-end fixing block 11, two front-end spindles 12, two rear-end spindles 13, and a rear-end fixing block 14; one narrow-side pad 1 is fixedly installed with the base 8 by hexagonal head screws 2, and the other narrow-side pad 1 is fixedly installed with the wide-side pad 5 by hexagonal head screws 2; one side of the winding wire after being bent into a U-shape is clamped by the narrow-side pad 1 and the base 8, and the other side is clamped by the narrow-side pad 1 and the wide-side pad 5. Both slots are secured with hexagonal head screws 2 to hold the winding wires. The wide-side pad 5 is equipped with a handle 6. When the handle 6 is turned, the part of the wide-side pad 5 holding the winding wires rotates with the guide rail 7, centered on the front spindle 12 and the rear spindle 13 mounted on the base 8, and with the distance between the spindle and the spindle on the wide-side pad 5 as the radius. The arc-shaped mold 9 is mounted together with the base 8 and the guide rail 7 through the rear spindle 14. One side of the U-shaped winding wire is fixed, while the other side rotates and pulls the U-shaped bent part along the arc-shaped mold 9 to form a hairpin winding.

[0006] The front mandrel 12 and the rear mandrel 13 have threads at both ends and a smooth middle section; each end of the wide-side pad 5 has a threaded hole for screwing into the front mandrel 12 and the rear mandrel 13 respectively; each end of the base 8 has a threaded hole for screwing into the front mandrel 12 and the rear mandrel 13; two guide rails 7 are located on the end faces of the base and the wide-side pad 5, and the two mandrels at each end pass through the inner hole of the guide rail 7 and are then screwed into the hexagonal nut 10 to ensure that the guide rail 7 does not move along the axial direction of the mandrel.

[0007] Both the front fixing block 11 and the rear fixing block 14 are flat pieces with rectangular cross-sections, which are interference-fitted with the wide-side pad block 5 and inserted into the inner hole of the guide rail 7.

[0008] The wide-edge pad 5 and the narrow-edge pad 1 are each equipped with two wide-edge pads 4 and two narrow-edge pads 3 of different thicknesses. One wide-edge pad is installed between the wide-edge pad 5 and the narrow-edge pad 1, and the other wide-edge pad is installed between the narrow-edge pad 1 and the base 8. The narrow-edge pad 3 is installed on the narrow-edge pad 1.

[0009] The wide-side pad 5 moves along the length of the inner hole of the guide rail 7 to adjust the radius of the winding wire bending; the rotation angle of the guide rail 7 can be freely adjusted, thereby adjusting the bending arc and span of the winding wire.

[0010] The narrow-edge pad 1 has a through hole on the front, which is fastened to the base 8 and the wide-edge pad 5 by an internal hexagonal head screw 2; the top surface has a threaded hole, into which narrow-edge adjusting shims 3 of different widths can be installed, and the side surface has a threaded hole, into which wide-edge adjusting shims 4 can be installed.

[0011] The wide-side pad 5 has round holes at both ends, which are interference fit with the front spindle 12 and the rear spindle 13, and all three move with the guide rail 7. It also has square holes at both ends, which are interference fit with the front fixing block 11 and the rear fixing block 14. It has a wire groove at the bottom to place the winding wire. It has a hole at the top to insert the handle 6. It has a threaded hole on the front to screw in the internal hexagonal head screw 2 to fit the narrow-side pad 1 and the wide-side pad 5 together.

[0012] The base 8 has openings at both ends near the bottom for inserting the front mandrel 12 and the rear mandrel 13, which pass through the guide rail 7; an opening on the front for fixing the narrow-edge pad 1 with an internal hexagonal head screw 2; a slot on the top for inserting the winding wire; and an opening on the top for adding a narrow-edge adjusting shim 3, which is fastened with a countersunk screw.

[0013] The arc-shaped mold 9 is attached to one side of the base 8 and serves as a support for the end of the hairpin winding during the drawing process. The lower part has a hole at the same position as the base 8 for the rear end mandrel 13 to pass through.

[0014] The beneficial effects of this invention are:

[0015] The design incorporates a universal motor hairpin winding forming fixture structure. Parameters such as enameled wire specifications, forming arc, radius, and span are all adjustable, enabling rapid forming of hairpin windings while conveniently adjusting parameters such as arc, radius, and span. It possesses strong versatility and can achieve rapid forming manufacturing of various motor hairpin windings. Attached Figure Description

[0016] Figure 1 This is the front view of the present invention;

[0017] Figure 2 This is the left view of the present invention;

[0018] Figure 3 Front and side views of narrow-edge pad 1;

[0019] Figure 4 Front and side views of wide-edge pad 5;

[0020] Figure 5 The main view and side view of guide rail 7;

[0021] Figure 6 The base 8 is shown in the front and side views.

[0022] Figure 7 The front and side views of the arc-shaped mold 9;

[0023] Figure 8 A schematic diagram of the front mandrel 12;

[0024] Figure 9 Schematic diagram of the rear end mandrel 13;

[0025] Figure 10 This is a schematic diagram showing two states during the molding process.

[0026] Among them: 1-narrow edge pad, 2-internal hexagonal head screw, 3-narrow edge adjusting shim, 4-wide edge adjusting shim, 5-wide edge pad, 6-handle, 7-guide rail, 8-base, 9-arc mold, 10-hexagonal nut, 11-front end fixing block, 12-front end spindle, 13-rear end spindle, 14-rear end fixing block, 15-countersunk screw. Detailed Implementation

[0027] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings.

[0028] like Figure 1 , Figure 2 As shown, the general motor hairpin winding forming tooling structure includes a narrow-side pad 1, an internal hexagonal head screw 2, a narrow-side adjusting shim 3, a wide-side adjusting shim 4, a wide-side pad 5, a handle 6, a guide rail 7, a base 8, an arc-shaped mold 9, a hexagonal nut 10, a front-end fixing block 11, a front-end spindle 12, a rear-end spindle 13, a rear-end fixing block 14, and a countersunk screw 15.

[0029] Narrow-edge pad 1 Figure 3 As shown, the front has a through hole, which is fastened to the base 8 and the wide-side pad 5 by an internal hexagonal head screw 2. The back has a threaded hole, which allows for the addition of narrow-side adjusting shims 3 of different thicknesses, which are fastened by countersunk screws 15. The top is a wire groove for placing the winding wire, and it also has a threaded hole, which allows for the addition of wide-side adjusting shims 4 of different thicknesses, which are fastened by countersunk screws 15.

[0030] Wide edge pad 5 such Figure 4 As shown. Both ends have round holes that are interference-fitted with the front spindle 12 and rear spindle 13, allowing all three to move simultaneously within the guide rail 7. Both ends have square holes that are interference-fitted with the front fixing block 11 and rear fixing block 14, ensuring the wide-side pad 5 does not rotate relative to the guide rail 7. There is a wire groove below for placing the winding wire. A hole is opened at the top for inserting a handle 6. A threaded hole is on the front for screwing in an internal hexagonal head screw 2 to fit the narrow-side pad 1 against the wide-side pad 5.

[0031] Guide rail 7 Figure 5 As shown. The guide rail 7 is fixed to both ends of the base 8 and the wide-side pad 5 by hexagonal nuts 10, and can rotate relative to the base 8. It has internal slots, allowing the wide-side pad 5 to move within the guide rail via the front spindle 12 and the rear spindle 13, thereby adjusting the radius of the winding wire formation. The wide-side pad 5 has a rectangular front fixing block 11 and a rectangular rear fixing block 14 at both ends, which pass through the guide rail 7 to ensure that the guide rail 7 does not rotate relative to the wide-side pad 5.

[0032] Base 8 Figure 6 As shown. Holes are opened near the bottom at both ends for inserting the front mandrel 12 and the rear mandrel 13, which pass through the guide rail 7. An opening at the top allows for fixing the narrow-edge pad 1 with an internal hexagon head screw 2, which can clamp and fix the winding wire. A slot is cut at the top for inserting the winding wire. An opening at the top allows for adding a narrow-edge adjusting pad 3, which is fastened with a countersunk screw 15, thereby enabling the forming of winding wires of different specifications.

[0033] Arc mold 9 Figure 7 As shown. The arc-shaped mold 9 is attached to one side of the base 8, serving as a support for the end of the hairpin winding during the drawing process. The lower part has a hole at the same position as the base 8 for the rear mandrel 13 to pass through.

[0034] Front spindle 12 Figure 8 As shown. Both ends are threaded, and the middle is smooth. The smooth side is installed into the guide rail 7, one end is threaded into the hexagonal nut 10, and the other end is threaded into the wide-side pad 5 or the base 8, so that the guide rail 7 can drive the wide-side pad 5, which is holding one side of the winding wire, to rotate relative to the base 8, while the base 8 holds the other side of the winding wire and remains stationary.

[0035] Rear end spindle 13 Figure 9 As shown. Its structure is basically similar to that of the front mandrel 12, with threads at both ends and a smooth surface in the middle. Since the rear end is the end direction of the hairpin wire, the guide rail 7 is separated from the hairpin end length by the wide edge pad 5 and the base 8. Therefore, the smooth shaft is divided into two sections, with a stepped surface serving as the limit for the guide rail 7.

Claims

1. A universal motor hairpin winding forming tool structure, comprising two narrow edge pads (1), internal hexagonal head screws (2), wide edge pads (5), handles (6), two guide rails (7), bases (8), arc-shaped dies (9), hexagonal nuts (10), front end fixing blocks (11), two front end spindles (12), two rear end spindles (13), rear end fixing blocks (14); one narrow edge pad (1) is fixedly installed with the base (8) through the internal hexagonal head screw (2), and the other narrow edge pad (1) is fixedly installed with the wide edge pad (5) through the internal hexagonal head screw (2); one side of the winding wire bent into a U shape is clamped by the narrow edge pad (1) and the base (8), and the other side is clamped by the narrow edge pad (1) and the wide edge pad (5). Both slots are fastened and clamped winding wires through the internal hexagonal head screw (2); the wide edge pad (5) is provided with the handle (6), the handle (6) is pulled, the wide edge pad (5) clamped winding wire part is driven by the guide rail (7), and the front end spindle (12) and the rear end spindle (13) installed on the base (8) are taken as the center, and the distance between the spindle and the spindle on the wide edge pad (5) is taken as the radius to realize rotation; the arc-shaped die (9) is assembled with the base (8) and the guide rail (7) through the rear end spindle (14); one side of the U-shaped winding wire is fixed, and the other side rotates while pulling the U-shaped bent part along the arc-shaped die (9) to form a hairpin winding.

2. The universal motor coil forming tooling structure of claim 1, wherein, The front end spindle (12) and the rear end spindle (13) are provided with threads at both ends and a smooth surface in the middle part; the wide edge pad (5) is provided with a threaded hole at both ends, respectively screwed into the front end spindle (12) and the rear end spindle (13), and the base (8) is also provided with a threaded hole at both ends, also screwed into the front end spindle (12) and the rear end spindle (13); the two guide rails (7) are located on the end faces of the base and the wide edge pad (5), the two spindles at each end pass through the inner hole of the guide rail (7), and the hexagonal nut (10) is screwed in to ensure that the guide rail (7) does not move along the axial direction of the spindle.

3. The universal motor coil forming tooling structure of claim 1, wherein, The front end fixing block (11) and the rear end fixing block (14) are both flat pieces with a rectangular cross section, and are in interference fit with the wide edge pad (5) and inserted into the inner hole of the guide rail (7).

4. The universal motor coil forming tooling structure of claim 1, wherein, The wide edge pad (5) and the narrow edge pad (1) are respectively provided with two pieces of wide edge pads (4) and narrow edge pads (3) with different thicknesses, one wide edge pad is installed between the wide edge pad (5) and the narrow edge pad (1), and the other wide edge pad is installed between the narrow edge pad (1) and the base (8); the narrow edge pad (3) is installed on the narrow edge pad (1).

5. The universal motor coil forming tooling structure of claim 1, wherein, The wide edge pad (5) moves in the length direction of the inner hole of the guide rail (7) to adjust the radius of the winding wire bending; the rotation angle of the guide rail (7) can be freely adjusted to adjust the bending radius and span of the winding wire.

6. The universal motor coil forming tooling structure of claim 1, wherein, The narrow edge pad (1) has a through hole on the front surface, is fastened with the base (8) and the wide edge pad (5) through the internal hexagonal head screw (2), has a threaded hole on the top surface, can be installed with the narrow edge adjusting pad (3) with different widths, and has a threaded hole on the side surface, can be installed with the wide edge adjusting pad (4).

7. The universal motor coil forming tooling structure of claim 1, wherein, Wide edge pad (5) both ends have round hole, with front end mandrel (12), rear end mandrel (13) for interference fit, three simultaneously with guide rail (7) movement; both ends open with square hole, with front end fixed block (11), rear end fixed block (14) interference fit; lower end has wire slot, put winding wire; top end opening, install the handle (6); front face has thread hole, spin into the inside hexagonal head screw (2), will be narrow edge pad (1) and wide edge pad (5) fit.

8. The universal motor coil forming tooling structure of claim 1, wherein, Base (8) near the bottom of both ends opening, for the installation of front end mandrel (12) and rear end mandrel (13), through the guide rail (7); front face opening, through the inside hexagonal head screw (2) will be narrow edge pad (1) fixed; top slot, for the installation of winding wire; top opening, can increase the narrow edge adjustment pad (3), through the countersunk screw fastening.

9. The universal motor coil forming tooling structure of claim 1, wherein, Arc die (9) close to the base (8) on one side, as the end of hairpin winding wire drawing forming process, support, the lower part with the base (8) same position has hole, for passing through the rear end mandrel (13).

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