A device for twisting flat wire at the end of armature winding of flat wire motor

Abstract

The present invention belongs to the technical field of motor armature winding production, and particularly relates to a flat wire twisting device for the end of a flat wire motor armature winding. It comprises: an ejection mechanism, including an ejection rod and an ejection disk coaxially arranged on the ejection rod; a twisting mechanism, including a plurality of wire insertion holes arranged along the circumference of the ejection rod; a power mechanism, used to drive the twisting mechanism so that the wire insertion holes rotate along the circumference of the ejection rod. The stator core is fixed on the ejection disk, and the straight portion of each U-shaped wire in the armature winding is inserted into the wire insertion hole. When the power mechanism drives the torsion mechanism to rotate, the wire insertion hole drives the portion of the U-shaped wire straight portion located therein to rotate relative to the stator core, thereby twisting the straight portion. It can save working steps, save manpower and time, and improve production efficiency.

Description

Technical Field

[0001] The invention belongs to the technical field of motor armature winding manufacturing, and in particular relates to a flat wire twisting device for the end of a flat wire motor armature winding. Background Art

[0002] The armature is an important component of the motor. The armature consists of two main parts: the stator core and the winding. The armature winding refers to the enameled copper wire installed on the armature by winding or inserting.

[0003] With the development of the times, the drive motors used in electric vehicles or other fields have begun to use enameled rectangular wires with a rectangular cross section as motor windings in pursuit of high efficiency and small size. This type of rectangular copper wire is formed into a U-shaped wire (such as a U-shaped wire with a zigzag portion 1a, a first straight portion 2a and a second straight portion 2b) Figure 1 As shown in the figure) and then inserted into the stator core slot, it is assembled with the stator core to form a winding with roughly neatly arranged straight sections (as shown in the figure) Figure 2 As shown), in order to meet the circuit connection requirements, the straight parts of each U-shaped wire in the winding need to be twisted at different angles to achieve the adjacent effect, and then welded or other methods are used to connect them tightly.

[0004] The invention patent with the authorization announcement number CN1237687C and the authorization announcement date of January 18, 2006 discloses a method for manufacturing stator windings, and discloses a step of twisting the U-shaped wire segments of the straight part. In order to achieve the twisting requirements required by the method, the twisting device and the person need to cooperate highly to twist every two layers from the outermost straight part to the innermost straight part of the winding. This method has complicated steps, and it is necessary to replace a different twisting mold every two layers, and twist three times to achieve the effect, which is time-consuming and labor-intensive. Summary of the invention

[0005] In order to solve the above technical problems, the present invention provides a device for twisting flat wires at the ends of armature windings of flat wire motors, which is characterized by comprising:

[0006] An ejection mechanism, comprising an ejection rod and an ejection disk coaxially arranged on the ejection rod;

[0007] The twisting and bending mechanism comprises a plurality of wire insertion holes arranged along the circumference of the ejection rod;

[0008] A power mechanism is used to drive the twisting mechanism to make the wire insertion hole rotate along the circumferential direction of the ejection rod.

[0009] The stator core of the armature is fixed on the ejector plate, and the straight part of each U-shaped wire in the armature winding is inserted into the wire insertion hole. When the power mechanism drives the torsion mechanism to rotate, the wire insertion hole drives the part of the straight part of the U-shaped wire located therein to rotate relative to the stator core, thereby twisting the straight part. This can save work steps, save manpower and time, and improve production efficiency.

[0010] Preferably, the twisting and bending mechanism includes a plurality of first gears arranged up and down along the same center of a circle, each first gear is equipped with a hollow shaft, these hollow shafts are coaxially arranged outside the ejector rod, and a twisting and bending mold provided with the wire insertion hole is installed on the hollow shaft; the power mechanism includes a transmission gear shaft and a motor driving the transmission gear shaft to rotate, and a plurality of second gears are axially arranged on the transmission gear shaft, the second gears correspond to the first gears one by one, and each second gear is meshed with the corresponding first gear.

[0011] Preferably, there are two transmission gear shafts, the first transmission gear shaft is provided with a second gear for meshing with the first gear on the odd-numbered hollow shaft, and the second transmission gear shaft is provided with a second gear for meshing with the first gear on the even-numbered hollow shaft. The motor drives the first transmission gear shaft to rotate to achieve the simultaneous twisting of the odd-numbered layers of the straight line portion of the U-shaped line of the flat wire motor armature winding, the motor drives the second transmission gear shaft to rotate to achieve the simultaneous twisting of the even-numbered layers of the U-shaped line of the flat wire motor armature winding, and the motor drives the first transmission gear shaft and the second transmission gear shaft to rotate simultaneously to achieve the simultaneous twisting of the odd-numbered layers and the even-numbered layers of the U-shaped line of the flat wire motor armature winding.

[0012] Preferably, there are two motors, the first motor is used to drive the first transmission gear to rotate, and the second motor is used to drive the second transmission gear to rotate.

[0013] Preferably, the power mechanism further includes a reducer matched with the motor, and the transmission gear shaft is arranged on the reducer.

[0014] Preferably, a spacer is provided between adjacent hollow shafts, and an upper bearing and a lower bearing are provided at both ends of the spacer. The gap between each layer of the hollow shaft is separated by the upper bearing and the lower bearing, and a spacer is provided between the two identical bearings to support the bearings and limit the position. The upper bearing and the lower bearing are identical bearings, so that they do not interfere with each other in rotation.

[0015] Preferably, the inner circumference of the wire insertion hole is chamfered, so that the straight portion of the U-shaped wire can be more effectively inserted into the wire insertion hole.

[0016] Preferably, it also includes upper and lower support plates arranged opposite to each other; the twisting mechanism and the transmission gear shaft are arranged between the upper support plate and the lower support plate. After the even-numbered layers of the straight-line part of the flat-wire motor armature winding are twisted with the odd-numbered layers of the straight-line part of the winding, the stator core is automatically ejected, thereby saving the time of manual handling and loading.

[0017] Preferably, the ejection mechanism further comprises a cylinder, one end of the ejection rod is connected to the cylinder, and the ejection disk is arranged at the other end of the ejection rod.

[0018] Preferably, the cylinder is fixed on the lower support plate, the ejector rod extends out of the upper support plate, and the twisting and bending mold is rotatably installed in the upper support plate.

[0019] The present invention has the following beneficial effects:

[0020] The invention provides a flat enameled wire twisting device for the end of the armature winding of a flat wire motor, which solves the forming process of the end of the armature winding of the flat wire motor. The device can twist the odd-numbered layers and the even-numbered layers of the straight part of the armature winding of the flat wire motor at the same time. The twisting angle and direction are controllable, which can save work steps, manpower and time, and improve production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It means that a single enameled flat wire with a rectangular cross section is formed into a roughly U-shaped U-shaped wire.

[0022] Figure 2 This is a three-dimensional diagram showing that the U-shaped wire is inserted into the stator core slot and cooperates with the stator core to form a winding with six layers of straight parts arranged roughly in an orderly manner.

[0023] Figure 3 This is a three-dimensional diagram showing the U-shaped wire inserted into the stator core slot and combined with the stator core to form a six-layer straight winding with roughly neat arrangement after being twisted.

[0024] Figure 4 The invention is a longitudinal sectional view of the main body of the flat wire twisting device for the end of the armature winding of a flat wire motor, which includes an ejection mechanism, a twisting mechanism and a power mechanism.

[0025] Figure 5 It is a three-dimensional diagram showing the ejection mechanism included in the twisting device.

[0026] Figure 6 It is a longitudinal sectional view showing the twisting mechanism included in the twisting device.

[0027] Figure 7 It is a top view of the six-layer twisting and bending mold in which the twisting and bending mechanism of each wire slot can be seen, and a partial three-dimensional view of each layer of the twisting and bending mold. DETAILED DESCRIPTION

[0028] The terms used herein are only used to describe the purpose of specific embodiments, and are not intended to limit the present invention. Unless otherwise defined, all terms used herein have the same meaning as those of ordinary skill in the art to which the present invention belongs. It will be further understood that common terms should be interpreted as having a meaning consistent with their meanings in the relevant field and the present disclosure. The disclosure will be considered as an example of the present invention, and is not intended to limit the present invention to specific embodiments.

[0029] The present invention is applied to a process of forming the end of the armature winding of a flat wire motor, wherein a single enameled flat wire with a rectangular cross section is formed into a U-shaped wire having a curved portion 1a, a first straight portion 2a and a second straight portion 2b (such as Figure 1 As shown in the figure) is inserted into the stator core slot and matched with the stator core to form a winding with roughly neatly arranged straight parts (as shown in the figure) Figure 2 As shown), in order to meet the circuit connection requirements, the straight parts of each U-shaped wire in the winding need to be twisted at different angles to achieve the adjacent effect, and then welded or other methods are used to connect them tightly.

[0030] Embodiment 1

[0031] like Figure 4-7 As shown, a twisting device for forming the armature winding end of a flat wire motor is used for twisting the enameled flat wire at the end of the armature winding of the flat wire motor during the forming process of the armature winding end of the flat wire motor. It includes an ejection mechanism, a twisting mechanism, a power mechanism, and an upper support plate 4 and a lower support plate 5 that are arranged oppositely.

[0032] The ejection mechanism includes an ejection rod 11, a cylinder 12, and an ejection plate 13. One end of the ejection rod 11 is connected to the cylinder 12, and the ejection plate 13 is coaxially arranged at the other end of the ejection rod. The cylinder 12 is fixed on the lower support plate 5, and the ejection rod 11 extends out of the upper support plate 4.

[0033] The twisting mechanism is installed between the upper and lower support plates. It includes a plurality of first gears 21 arranged up and down along the same center of a circle, each of which is equipped with a hollow shaft 22, which is coaxially arranged outside the ejector rod 11, and a twisting mold 23 with a wire insertion hole 231 is installed on the hollow shaft 22. There are six hollow shafts 22 in this embodiment, and a hole for the twisting mold 23 to rotate is provided on the upper support plate 4. The top heights of each hollow shaft 22 are approximately at the same height, so that the twisting mold 23 installed at the top of the hollow shaft 22 is approximately located in the hole on the upper support plate 4. The heights of the six hollow shafts 22 are gradually shortened from the inside to the outside, so that the bottom ends of each layer of hollow shafts 22 are exposed to the outside and can be meshed with the second gear on the transmission gear shaft also arranged between the upper and lower support plates in the power structure. A spacer 24 is provided between adjacent hollow shafts 22, and an upper bearing 251 and a lower bearing 252 are provided at both ends of the spacer 24, respectively. The twisting and bending molds 23 on each hollow shaft 22 are different, but they all have wire insertion holes 231 neatly arranged along their circumference:

[0034] The bending die 23a on the outermost hollow shaft (the first hollow shaft) is a smooth surface without grooves on both the inner and outer sides. The outer side has closed grooves corresponding to the straight line portions in the first layer at the end of the straight line portion of the armature winding U-shaped wire (i.e., the wire insertion holes of the bending die 23a). The "closed" mentioned here and below refers to the end surface cover of the groove. The closed grooves are evenly distributed around the bending die 23a near the inner side. The inner side of the bending die 23a is in contact with the outer side of the bending die 23b on the second hollow shaft (such as Figure 7 as shown).

[0035] The twisting die 23b is a smooth surface without grooves on the inner circumference, and has an open groove on the outer circumference corresponding to each straight line portion in the second layer of the end of the straight line portion of the armature winding U-shaped wire (i.e., the wire insertion hole of the twisting die 23b). The "closed" mentioned here and below means that there is a notch at the end face of the groove and it is not closed. This groove surface is in contact with the outer circumference of the twisting die 23c on the third layer of the hollow shaft. Figure 7 shown)

[0036] The outer circumference of the bending die 23c is a smooth surface without grooves, and the inner circumference has open grooves corresponding to the straight parts of the third layer of the straight part end of the armature winding U-shaped wire (i.e., the wire insertion holes of the bending die 23c). The inner circumference of the bending die 23c is attached to the outer circumference of the bending die 23d on the fourth layer of the hollow shaft (such as Figure 7 as shown).

[0037] The inner and outer circumferences of the bending die 23d are both smooth surfaces without grooves. The grooves of the bending die 23d (i.e., the wire insertion holes of the bending die 23d) are opened inside and are closed, corresponding to each straight line portion in the fourth layer of the straight line end of the armature winding U-shaped wire. The closed grooves are evenly distributed in the circumference of the bending die 23d, and the inner circumference of the bending die 23d is in contact with the outer circumference of the bending die 23e on the fifth layer of the hollow shaft. (As shown in Figure 7 as shown).

[0038] The inner and outer circumferences of the bending die 23e are smooth surfaces without grooves. The grooves of the bending die 23e are opened inside the bending die 23e and are closed (i.e., the wire insertion holes of the bending die 23e), corresponding to each straight line portion in the fifth layer of the end of the straight line portion of the armature winding U-shaped wire. The closed grooves are evenly distributed in the bending die 23e in the circumferential direction, and the inner circumference of the bending die 23e is in contact with the outer circumference of the bending die 23f on the sixth layer of the hollow shaft (such as Figure 7 as shown).

[0039] The twisting die 23f is a smooth surface without grooves on the inner circumference, and has open grooves on the outer circumference corresponding to the straight portions in the sixth layer of the end of the straight portion of the U-shaped wire of the armature winding (i.e., the wire insertion holes of the twisting die 23f). The open grooves are evenly distributed around the twisting die 6f (such as Figure 7 as shown).

[0040] Preferably, the inner circumference of each wire insertion hole is provided with a chamfer to facilitate more effective insertion of the straight portion of the U-shaped wire into the wire insertion hole.

[0041] The power mechanism is used to drive the twisting mechanism so that the insertion hole 231 rotates along the circumference of the ejector rod 11. The power mechanism 3 of this embodiment includes a transmission gear shaft 31, a reducer 32, and a motor 33. The transmission gear shaft is installed on the lower support plate 5 and is located between the upper and lower support plates. A plurality of second gears 311 are arranged axially, and the second gears 311 correspond to the first gears 21 one by one, and each second gear 311 is meshed with the corresponding first gear 21. There are two transmission gear shafts 31, and the first transmission gear shaft is provided with 3 second gears for meshing with the first gears on the odd-numbered hollow shafts (the 1st, 3rd, and 5th layers of hollow shafts), and the second transmission gear shaft is provided with 3 second gears for meshing with the first gears on the even-numbered hollow shafts (the 2nd, 4th, and 6th layers of hollow shafts). There are two motors 33, the first motor is used to drive the first transmission gear to transmit, and the second motor is used to drive the second transmission gear to rotate. The two reducers 32 are respectively matched with the two motors, and the two transmission gear shafts are respectively arranged on the two reducers.

[0042] The method for forming the end of the armature winding of a flat wire motor using the twisting device of this embodiment includes:

[0043] 1. A single enameled flat wire with a rectangular cross section is formed into a U-shaped wire having a curved portion 1, a first straight portion 2a and a second straight portion 2b (such as Figure 1 As shown in the figure, the stator core has core slots arranged radially in the circumferential direction. Any straight line portion of the first straight line portion 2a or the second straight line portion 2b of the U-shaped wire is inserted close to the inner side of the core slot, and the other straight line portion is inserted close to the inner side of another core slot with a reasonable span. Every two or three U-shaped wires form a U-shaped wire group. Multiple U-shaped wire groups can be arranged in the same pattern in the circumferential direction to form a layer of winding, and can be stacked into six layers of winding from the outer side of the core to the inner side of the core (such as Figure 2 As shown in the figure, the windings roughly fill the core slots. In this case, several U-shaped wire straight portions are led out along the stator slots to form six layers of winding straight portions that are roughly perpendicular to the lower end surface of the stator core and downward, and each layer has a roughly circular end portion (as shown in the figure). Figure 2 as shown).

[0044] 2. The stator core is carried manually or mechanically, and the stator core is matched with the outer peripheral side of the ejector plate on the ejector mechanism of the twisting device near the lower end surface of the inner side of the winding and is roughly perpendicular to the ejector rod. The cylinder 12 in the ejector mechanism drives the ejector rod 11 to make the ejector plate 13 provided at the other end of the ejector rod 11 descend (the ejector rod 11 is centrally assembled with the ejector plate 13 and is perpendicular to the ejector plate 13, and the other end is connected to the piston rod of the cylinder 12) so that the lead straight line parts of each layer of the six-layer winding at the end of the straight line part of the winding are inserted into the corresponding grooves (i.e., insertion holes) in the corresponding twisting molds of the six layers in the twisting mechanism along the chamfer, and each straight line part corresponds to each groove one by one.

[0045] 3. After the straight portion led out from the odd layers of the six-layer winding at the end of the straight portion of the winding is inserted into the odd-layer twisting mold among the six twisting molds, the first motor in the twisting mechanism increases the torque through the reducer, and drives the first transmission gear shaft connected to the reducer to rotate in the same direction as the first motor. The three second gears of the same size and axially evenly distributed on the first transmission gear shaft are meshed from top to bottom with the first gear of the odd-layer hollow shaft installed in the gear set, and further drive these first gears to rotate in the opposite direction of the rotation direction of the first transmission gear shaft, and finally drive the twisting molds 23a, 23c, 23e on the odd-layer hollow shaft to rotate in the same direction as the first gear in the gear set.

[0046] After the straight portion led out from the even-numbered layers of the six-layer winding at the end of the straight portion of the winding is inserted into the even-numbered twisting mold among the six twisting molds, the second motor in the twisting mechanism increases the torque via the reducer, and drives the second transmission gear shaft connected to the reducer to rotate in the same direction as the second motor. The three second gears of the same size and axially evenly distributed on the second transmission gear shaft are meshed from top to bottom with the first gear of the even-numbered hollow shaft installed in the gear set, and further drive these first gears to rotate in the opposite direction of the rotation direction of the first transmission gear shaft, and finally drive the twisting molds 23b, 23d, and 23f on the even-numbered hollow shaft to rotate in the same direction as the first gear in the gear set.

[0047] The first motor and the second motor often rotate simultaneously, or they can rotate separately. After rotating simultaneously, the ends of the straight line parts of the U-shaped wires of the armature winding of the flat wire motor are twisted and bent by six-layer twisting dies respectively. Figure 3 The first motor and the second motor determine the number of rotations of the gears in the twisting mechanism, which further determines the twisting angle of the straight line portion of each layer in the end of the straight line portion of the winding U-shaped line driven by the corresponding twisting die.

[0048] After the end of the straight portion of the winding is twisted, the ejection mechanism is activated, and the piston rod of the cylinder 12 applies a thrust upward, further driving the ejection rod 11 installed on the cylinder 12, further causing the ejection plate 13 provided at the other end of the ejection rod 11 to rise, further driving the twisted stator core to rise.

[0049] Finally, the stator core is moved manually or mechanically.

[0050] Although the embodiments of the present invention have been described, a person skilled in the art may make various changes or modifications within the scope of the appended claims.

Claims

1. A device for twisting flat wires at the ends of armature windings of flat wire motors, characterized in that: include: An ejection mechanism, comprising an ejection rod and an ejection disk coaxially arranged on the ejection rod; The twisting and bending mechanism comprises a plurality of wire insertion holes arranged along the circumference of the ejection rod; A power mechanism, used for driving the twisting mechanism to make the wire insertion hole rotate along the circumferential direction of the ejection rod; The twisting mechanism includes a plurality of first gears arranged vertically along the same center of a circle, each of which is equipped with a hollow shaft, which are coaxially arranged outside the ejector rod, and a twisting mold provided with the wire insertion hole is installed on the hollow shaft; The power mechanism includes a transmission gear shaft and a motor driving the transmission gear shaft to rotate, and a plurality of second gears are arranged in the axial direction of the transmission gear shaft, and the second gears correspond to the first gears one by one, and each second gear is meshed with the corresponding first gear; The inner circumference of the wire insertion hole is provided with a chamfer.

2. A device for twisting flat wires at the ends of armature windings of flat wire motors according to claim 1, characterized in that: There are two transmission gear shafts, the first transmission gear shaft is provided with a second gear for meshing with the first gear on the odd-numbered hollow shafts, and the second transmission gear shaft is provided with a second gear for meshing with the first gear on the even-numbered hollow shafts.

3. A device for twisting flat wires at the ends of armature windings of flat wire motors according to claim 2, characterized in that: There are two motors for driving the transmission gear shaft to rotate. The first motor is used to drive the first transmission gear to rotate, and the second motor is used to drive the second transmission gear to rotate.

4. The device for twisting flat wires at the ends of armature windings of flat wire motors according to claim 1, characterized in that: The power mechanism also includes a reducer matched with the motor, and the transmission gear shaft is arranged on the reducer.

5. The device for twisting flat wires at the ends of armature windings of flat wire motors according to claim 1, characterized in that: A spacer sleeve is arranged between adjacent hollow shafts, and an upper bearing and a lower bearing are respectively arranged at two ends of the spacer sleeve.

6. The device for twisting flat wires at the ends of armature windings of flat wire motors according to claim 1, characterized in that: It also includes an upper support plate and a lower support plate that are arranged relatively; The twisting mechanism and the transmission gear shaft are both arranged between the upper support plate and the lower support plate.

7. A device for twisting flat wires at the ends of armature windings of flat wire motors according to claim 6, characterized in that: The ejection mechanism further includes a cylinder, one end of the ejection rod is connected to the cylinder, and the other end of the ejection rod is provided with the ejection disk.

8. The device for twisting flat wires at the ends of armature windings of flat wire motors according to claim 7, characterized in that: The cylinder is fixed on the lower support plate, the ejector rod extends out of the upper support plate, and the twisting and bending die is rotatably installed in the upper support plate.

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