Hairpin type stator coil forming device and forming method

Abstract

The present invention provides a hairpin type stator coil forming device, which includes: a first forming machine, which is configured to make the central part of the material coil protrude upward to form a vertex on the material coil, and form inclined portions inclined to both sides of the vertex; a second forming machine, which is configured to load the material coil bent and formed by the first forming machine, and form a front / rear bent portion on the material coil by bending and forming a part of the inclined portion on one side and a part of the inclined portion on the other side based on the vertex; and a third forming machine, which is configured to load the material coil bent and formed by the second forming machine, and form the inclined portion into a circle in the front-to-rear direction.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the priority benefit of Korean Patent Application No. 10-2019-0123902 filed on October 7, 2019, in the Korean Intellectual Property Office, which is hereby incorporated by reference. Technical Field

[0003] The invention relates to a hairpin-type stator coil forming device and a forming method. Background Art

[0004] Generally, a hybrid vehicle or an electric vehicle, which is called an eco-friendly vehicle, can generate driving force by an electric motor (hereinafter referred to as a “driving motor”) that obtains rotational power from electric energy.

[0005] A hybrid vehicle can be driven in an electric vehicle (EV) mode, which is a pure electric vehicle mode using only the power of a drive motor, or a hybrid vehicle (HEV) mode, which uses rotational power of both an engine and a drive motor as power sources.

[0006] In addition, a general electric vehicle runs using the rotational power of a drive motor as a power source.

[0007] For example, most of the driving motors used as a power source of environmentally friendly vehicles use a permanent magnet synchronous motor (PMSM).

[0008] As such, a driving motor as a permanent magnet synchronous motor used as a power source for an environmentally friendly vehicle basically includes a stator generating magnetic flux, a rotor spaced apart from the stator by a predetermined gap and performing a rotational motion, and a permanent magnet mounted on the rotor.

[0009] Here, a plurality of slots are formed in the stator on the inner peripheral side of the stator core, and a stator coil is wound in each slot.

[0010] When alternating current is applied to the stator coil, a rotating magnetic field is generated in the stator, and a rotating torque can be generated in the rotor through the rotating magnetic field.

[0011] According to the winding method of the stator coil, the drive motor can be divided into a distributed winding type drive motor and a centralized winding type drive motor, and according to the coil winding method, the stator of the distributed winding type drive motor can be divided into a segmented coil stator and a distributed winding coil stator.

[0012] In this case, the segmented coil stator is a stator manufactured by a method of preforming a coil into a predetermined shape and then inserting it into a slot of a stator core, and the distributed winding coil stator is a stator manufactured by a method of inserting a bundle of coils into the slot of a stator core.

[0013] Meanwhile, it is known that the output of a driving motor is proportional to the number of turns of a coil wound around a stator core.

[0014] However, when the number of turns of the coil increases, the size of the stator core or the driving motor is inevitably increased, which makes it difficult to reduce the size of the driving motor.

[0015] Therefore, in order to increase the output of the drive motor without increasing the size of the drive motor, a method of increasing the stacking factor of the coil wound around the stator core may be considered.

[0016] In other words, a method of increasing the space factor of the coil by minimizing a dead space between the stator core and the wound coil or a dead space between the respective coils may be considered.

[0017] In the above aspects, in order to replace the use of a toroidal coil with a circular cross section (referred to as a "toroidal wire" in the art) as a coil winding, a method of using a flat coil with a square cross section (referred to as a "flat wire" in the art) has been actively studied.

[0018] Compared with toroidal coils, flat coils can reduce dead space and increase space factor due to their cross-sectional shape.

[0019] However, compared with the toroidal coil, the flat coil has difficulty in the coil winding work.

[0020] This is because flat coils are manufactured with a wider cross-section compared to toroidal coils in order to maximize the space factor, making it difficult to use a winding machine.

[0021] Therefore, as a method for easily performing coil winding operations of flat coils in a segmented coil stator of a distributed winding type drive motor, a method is proposed in which a plurality of separate hairpin-type (roughly U or V-shaped) stator coils (also referred to as "conductors" in the art) are inserted into each slot of a stator core and radially adjacent stator coils in the slots are welded to continuously form a coil winding of the stator core.

[0022] The drive motor having the hairpin wound type stator manufactured by the above method is also referred to as a "hairpin type drive motor" in the art.

[0023] According to the stator coil winding structure of the above-mentioned hairpin type drive motor, the limitations caused by the winding machine can be overcome, and the winding operation can be relatively easy even in the case of a square coil. In addition, a high-output and small motor can be achieved by increasing the duty cycle of the coil.

[0024] On the other hand, the process of forming the hairpin type stator coil as described above into a predetermined shape can be roughly divided into a computer numerical control (CNC) forming method and a stamping forming method, and since there are several types of hairpins in one hairpin type drive motor, it is advantageous to use a CNC forming method that can be applied to multiple models.

[0025] However, according to the CNC forming method that can be applied to a variety of models, the production speed of one hairpin is about 6 seconds, which is a bit slow, while according to the fast stamping forming method, the production speed of one hairpin is about 3 seconds, which has twice the productivity compared with the CNC forming method, but the stamping forming method can only produce a single model.

[0026] Therefore, it is necessary to research and develop the forming method of the hairpin.

[0027] The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art already known to a person skilled in the art. Summary of the invention

[0028] The present invention relates to a hairpin-type stator coil forming device and forming method. A specific embodiment relates to a hairpin-type stator coil forming device and forming method that can form stator coils corresponding to multiple models.

[0029] The embodiments of the present invention provide a hairpin-type stator coil forming device and forming method capable of producing various types of stator coils.

[0030] An embodiment of the present invention provides a hairpin-type stator coil forming device, which includes: a first forming machine, which makes the central part of the material coil protrude upward to form a vertex, and forms inclined portions inclined to both sides of the vertex; a second forming machine, in which the material coil bent and formed by the first forming machine is loaded, and a front / rear bent portion is formed by bending a part of the inclined portion on one side and a part of the inclined portion on the other side with the vertex as a reference; and a third forming machine, in which the material coil bent and formed by the second forming machine is loaded, and the inclined portion is formed into a circle in the front-to-rear direction.

[0031] The first forming machine may include: a lower central die, configured to have a forming surface with a triangular cross-section; lower left and right dies, configured to be slidable in the left-right direction on both sides of the forming surface connected to the lower central die, and to adjust the length of the inclined portion of the material coil; a movable bracket, configured to be supported by a frame at the upper part of the lower central die, and to be movable up and down from the upper part of the frame; an upper spring component, configured to be set at a predetermined distance from each other on both sides with the center of the forming surface of the lower central die as a reference through the movable bracket, and when the movable bracket moves downward, the material coil is press-fitted toward the lower central die, so that a vertex and an inclined portion are formed on the material coil by the forming surface; and an upper roller component, configured to be set on both outer sides of the upper spring component through the movable bracket, and to adjust the length of the inclined portion by pressing the material coil with the lower left and right dies as a reference.

[0032] The upper portion of the lower central mold may be provided with a forming surface for forming an inclined portion and a vertex on the material coil, and both sides of the lower central mold are formed with mounting grooves for mounting the lower left and right molds.

[0033] The lower left and right molds may be installed to be slidable in left and right directions in the installation grooves by operation of a motor.

[0034] The moving bracket may be movably mounted up and down on a screw rod rotated by a motor mounted on the frame, and a moving position of the moving bracket is limited by a stopper provided at a lower end portion of the screw rod.

[0035] The upper spring component may include: a spring installed in a snap-fit ​​hole formed on the moving bracket; a spring rod arranged on the inner side of the spring and installed to pass through the upper part of the frame; and a spring block connected to one end of the spring rod and molded into the material coil toward the lower center as the moving bracket moves downward.

[0036] The upper roller component may include: a support rod installed on a movable bracket; and a roller rotatably installed at the front end of the support rod, so that as the movable bracket moves downward, the material coil is bent toward the left and right dies and pressed into the material coil toward the left and right dies.

[0037] The first forming machine may further include: a cutting component installed on the rear side of the direction of supplying the material coil and cutting the material coil to a set length, wherein the cutting component may include: a cutting die arranged below the material coil; and a cutter arranged on the upper side corresponding to the cutting die and driven in the up and down directions.

[0038] The second forming machine may include: an upper mold and a lower mold, the vertex and the inclined portion of the material coil formed by the first forming machine are between the upper mold and the lower mold, and step surfaces can be respectively formed on the inner surfaces of the upper mold and the lower mold facing each other, and the vertex is formed to form a front / rear curved portion, so that the inclined portion on one side and the inclined portion on the other side are located on different lines with the vertex of the material coil as a reference.

[0039] The third forming machine may include: clamping parts respectively provided corresponding to both ends of the inclined portion of the material coil formed by the second forming machine so that the inclined portion is clamped by a clamping pin.

[0040] The clamping component may include: a first clamping component, which can move forward and backward with the center of the rack as a reference through a guide member when clamping the inclined portion on one side; and a second clamping component, which is installed to rotate together with the rack rotated by the pinion, and rotates in one direction relative to the fixed first clamping component when clamping the inclined portion on the other side.

[0041] The clamping member may be configured to rotate in a state where the material coil is clamped by the clamping pin to adjust the roundness of the inclined surface.

[0042] Another embodiment of the present invention provides a hairpin stator coil forming method for forming a hairpin stator coil using a hairpin stator coil forming device, the hairpin stator coil including a front / rear bent portion formed at a vertex by bending a material coil, an inclined portion inclined downward to both sides from the front / rear bent portion and formed into a circle in the front-to-back direction, and a leg portion connected downward from the inclined portion, the method comprising: a first step of cutting the material coil at a predetermined length by a first forming machine, and forming a vertex and an inclined portion on the material coil; a second step of loading the vertex and the inclined portion so that the vertex and the inclined portion are interposed between an upper mold and a lower mold, and forming the vertex into a front / rear bent portion by combining the upper mold and the lower mold so that the inclined portion on one side and the inclined portion on the other side are located on different lines with the vertex as a reference; and a third step of loading both ends of the inclined portion so that the both ends of the inclined portion are interposed between clamping pins, and rotating the clamping component so that the inclined portion is formed into a circle in the front-to-back direction.

[0043] The first step may include: allowing the material coil to enter the upper part of the lower central mold; cutting the material coil by a cutting component arranged on the rear side of the entry direction of the material coil; moving the movable bracket downward so that the upper spring component is pressed into the material coil toward the forming surface of the lower central mold, thereby forming a vertex and an inclined portion on the material coil along the forming surface; and allowing the movable bracket to continue to move downward so that the upper roller component is pressed into the material coil along the lower left and right molds.

[0044] The first step may further include: when the upper roller member moves downward to press the material coil toward the lower left and right dies, moving the lower left and right dies in the left and right directions to be loaded at a predetermined position.

[0045] The second step may include: after the first step, loading the material coil so that the apex and the inclined portion are between the upper mold and the lower mold; and forming the apex into a front / rear curved portion by combining the upper mold and the lower mold so that the inclined portion on one side and the inclined portion on the other side are located on different lines based on the apex.

[0046] The third step may include: after the second step, loading the material coil so that both ends of the inclined portion are between the clamping pins; and in a state where the material coil is clamped by the clamping pins, rotating the second clamping component in one direction relative to the first clamping component, so that the inclined portion of the material coil is formed into a circle in the front-to-back direction.

[0047] The first clamping member may be driven along the guide in a direction towards or away from the second clamping member.

[0048] In the third step, the bending amount of the inclined portion in the front-rear direction can be determined according to the rotation angle of the second clamping member.

[0049] The hairpin type stator coil forming device and forming method according to the embodiment of the present invention can set the length of the inclined portion of the material coil, the angle of the apex between the inclined portions, the degree of curvature of the inclined portion, etc. by only changing the setting values ​​input to the first forming machine, the second forming machine, and the third forming machine. Therefore, it can be applied to the production of various types of stator coils, and a single device can be used to handle multiple models, thereby improving productivity.

[0050] Furthermore, effects that can be obtained or expected from the embodiments of the present invention are directly or implicitly described in the following detailed description. That is, various effects expected from the embodiments of the present invention will be described in the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0051] Figure 1 A schematic diagram showing the structure of a hairpin-type stator coil of a drive motor applied to an embodiment of the present invention.

[0052] Figure 2 A schematic diagram of a hairpin type stator coil forming device according to an embodiment of the present invention is shown.

[0053] Figure 3 A schematic diagram of a first forming machine applied to a hairpin-type stator coil forming device according to an embodiment of the present invention is shown.

[0054] Figure 4 and Figure 5A schematic diagram of a second forming machine applied to a hairpin-type stator coil forming device according to an embodiment of the present invention is shown.

[0055] Figure 6 A schematic diagram of a third forming machine applied to a hairpin-type stator coil forming device according to an embodiment of the present invention is shown.

[0056] Figures 7 to 15 A schematic diagram showing a forming method of forming a stator coil using a hairpin-type stator coil forming device according to an embodiment of the present invention. DETAILED DESCRIPTION

[0057] Hereinafter, the present invention will be described more fully with reference to the accompanying drawings, in which embodiments of the present invention are shown. As those skilled in the art will realize, the described embodiments may be modified in various different ways without departing from the spirit or scope of the present invention.

[0058] In order to clearly describe the embodiments of the present disclosure, parts irrelevant to the description are omitted, and the same reference numerals denote the same elements throughout the specification.

[0059] Furthermore, in the following detailed description, terms for elements in the same relationship are classified as “first,” “second,” etc., but embodiments of the present invention are not necessarily limited to the order in the following description.

[0060] Figure 1 A schematic diagram showing the structure of a hairpin-type stator coil of a drive motor applied to an embodiment of the present invention.

[0061] Reference Figure 1 , the hairpin type stator coil applied to the drive motor of the embodiment of the present invention can be applied to a drive motor of a hybrid vehicle and / or an electric vehicle which is an environmentally friendly vehicle that obtains driving force from electric energy.

[0062] For example, the drive motor may use a permanent magnet synchronous motor (PMSM).

[0063] In an embodiment of the present invention, the driving motor includes a stator 1 , a rotor (not shown) spaced apart from the stator 1 by a predetermined gap, and a plurality of permanent magnets (not shown) mounted on the rotor.

[0064] The stator 1 includes a stator core 3 where a plurality of electric steel plates are stacked, and a hairpin type stator coil 7 (generally referred to as “conductor” in the art) is wound on the stator core 3 through a plurality of slots 5 .

[0065] Furthermore, the rotor includes a rotor core in which a plurality of electrical steel sheets are stacked in an axial direction.

[0066] The above-mentioned permanent magnets are inserted into and mounted in insertion holes provided in the rotor core.

[0067] Here, the drive motor may be an internal synchronous motor in which a rotor is provided inside a stator 1 , or an external synchronous motor in which a rotor is provided outside a stator 1 .

[0068] The above-mentioned hairpin type stator coil 7 is a flat coil, for example, the hairpin type stator coil 7 includes a front / rear bent portion 17 formed in the central part of the hairpin type stator coil 7, an inclined portion 11 formed downward on both sides based on the front / rear bent portion 17, and a leg portion 15 formed vertically below each inclined portion 11. The overall shape of the hairpin type stator coil 7 is an inverted U-shaped or V-shaped hairpin shape, and the hairpin type stator coil 7 is a flat coil with a quadrilateral cross-section.

[0069] In this case, in the hairpin type stator coil 7, with the front / rear bent portion 17 as a reference, one side inclined portion is formed to protrude forward or backward than the other side inclined portion, and the entire shape of the inclined portion 11 can be formed into a circle forward or backward.

[0070] The hairpin type stator coil 7 is inserted into the fixed layer of the slot 5 (indicated by the dotted line in the figure), and the ends of a pair of legs 15 protrude outside the slot 5, and when the protruding parts are welded and joined, an electrically connected coil winding can be formed.

[0071] As described above, although an embodiment of the present invention has been described in which a hairpin type stator coil is applied to a stator in a drive motor of an environmentally friendly vehicle, the scope of the present invention is not limited thereto, and the technical scope of the present invention is applicable to any drive motor provided with hairpin type stator coils of various types and purposes.

[0072] Figure 2 A schematic diagram of a hairpin type stator coil forming device according to an embodiment of the present invention is shown.

[0073] The hairpin type stator coil forming apparatus according to an embodiment of the present invention basically includes a first forming machine 100 , a second forming machine 200 , and a third forming machine 300 , and will be described for each configuration.

[0074] Regarding the hairpin type stator coil 7 according to the embodiment of the present invention, the material coil 10 in a straight line shape is supplied to the first forming machine 100 to be bent and formed in the first forming machine 100, thereby forming the inclined portion 11, the vertex 13 and the leg portion 15. The material coil 10 formed in the first forming machine 100 is conveyed to the second forming machine 200 by a conveying jig to form the front / rear bent portion 17, and the material coil 10 formed in the second forming machine 200 is conveyed to the third forming machine 300 by a conveying jig to form the inclined portion 11 into a round shape, thereby finally completing the hairpin type stator coil 7.

[0075] Figure 3A schematic diagram of a first forming machine applied to a hairpin-type stator coil forming device according to an embodiment of the present invention is shown.

[0076] In this manual, based on Figure 3 , the entry direction of the material coil 10 described below is set to the left and right direction as the reference direction, the upward part is defined as the upper part, upper end, upper surface and upper end, and the downward part is defined as the lower part, lower end, lower surface and lower end.

[0077] Furthermore, hereinafter, “end (one end or the other end)” may be defined as either end, or may be defined as a predetermined portion (one end or the other end) including the end.

[0078] Reference Figure 3 , a material coil 10 in a straight shape is supplied to the first forming machine 100 from a stator coil supply device (not shown).

[0079] Briefly describing the stator coil supply device, the stator coil supply device unwinds the flat material coil 10 wound on the coil unwinder, flattens the material coil 10 through the coil straightener, and then supplies the flattened material coil 10 to the first forming machine 100 according to the embodiment of the present invention.

[0080] As described above, the first forming machine 100 receiving the material coil 10 from the stator coil supply device bends and forms the material coil 10 such that the central portion of the material coil 10 protrudes to one side to form the inclined portion 11 while forming the apex 13 .

[0081] The first molding machine 100 includes a lower central mold 110 , lower left and right molds 120 , a moving bracket 130 , an upper spring member 140 , an upper roller member 150 , and a cutting member 160 .

[0082] The lower center mold 110 is disposed to correspond to the lower center of the material coil 10 .

[0083] The lower center mold 110 has a molding surface 111 whose cross section in the up-down direction is a triangular cross section.

[0084] In the lower center die 110, a forming surface 111 has a predetermined width in the front-rear direction so that the material coil 10 can be placed.

[0085] The forming surface 111 is fixed to the frame F at a position other than a portion where the material coil 10 is placed.

[0086] The lower center die 110 is configured to form the inclined portion 11 and the vertex 13 on the material coil 10 through the forming surface 111 .

[0087] In addition, the lower central mold 110 may be provided to be movable in the up and down directions by a first motor M1 provided at the lower side of the lower central mold 110 .

[0088] Both sides of the lower central mold 110 are formed with mounting grooves 113 , and the lower left and right molds 120 are mounted in the mounting grooves 113 to be slidable in the left and right directions.

[0089] Both sides of the lower central mold 110 connected to the forming surface 111 may be formed with mounting grooves 113 .

[0090] The lower left-right mold 120 may be installed to be slidable in the left-right direction in the installation groove 113 by operation of the second motor M2 .

[0091] The lower left and right molds 120 may be guided by a separate member (not shown) that may slide in the mounting groove 113 , such as a roller member.

[0092] The lower left and right dies 120 may be connected to the forming surface 111 to adjust the length of the inclined portion 11 of the material coil 10 according to the movement of the lower left and right dies 120 .

[0093] For example, when the lower left and right molds 120 move toward their respective outer sides, the length of the inclined portion 11 may be formed to be longer.

[0094] In addition, the moving bracket 130 may be disposed above the lower central mold 110 and the lower left and right molds 120 .

[0095] The mobile support 130 may be supported by a frame F fixed to the ground.

[0096] The moving bracket 130 is installed on a screw rod 131 vertically provided from the upper portion of the frame F to be able to move up and down along the screw rod 131 .

[0097] The moving bracket 130 is movably mounted up and down on a screw 131 rotated by a third motor M3 mounted on the upper portion of the frame F, and a moving position of the moving bracket 130 may be limited by a stopper 133 provided at a lower end portion of the screw 131 .

[0098] The upper spring member 140 and the upper roller member 150 are installed on the moving bracket 130 .

[0099] The upper spring members 140 are installed through the moving bracket 130 at two positions spaced apart from each other by a predetermined gap with reference to the center of the forming surface 111 of the lower central mold 110 .

[0100] The upper spring component 140 includes a snap-fit ​​end 141 , a spring 143 , a spring block 145 and a spring rod 147 .

[0101] The engaging end 141 is assembled through the engaging hole 135 formed in the moving bracket 130 to fix the upper spring member 140 .

[0102] The spring 143 may be connected to the engaging end 141 , and may be made of a material having relatively strong elasticity.

[0103] In addition, the spring rod 147 is disposed at the inner side of the spring 143 , and the spring rod 147 may be installed at the upper portion of the frame F through the moving bracket 130 .

[0104] The spring rod 147 may limit the position of the spring 143 , and the spring block 145 is connected to an end of the spring rod 147 .

[0105] The spring block 145 is a portion that directly contacts the material coil 10 , and is preferably made of a material that does not cause scratches or the like on the surface of the material coil 10 when the spring block 145 contacts and is pressed into the surface of the material coil 10 .

[0106] As the moving bracket 130 moves downward, the upper spring member 140 may be pressed into the material coil 10 toward the lower center die 110 .

[0107] The upper spring member 140 may be pressed into the material coil 10 toward the lower central die 110 , so that an inclined portion 11 and an apex 13 are formed on the material coil 10 along a forming surface 111 of the lower central die 110 .

[0108] The moving bracket 130 is installed with an upper roller member 150 , wherein the upper roller members 150 are respectively disposed on two outer sides of the upper spring member 140 .

[0109] The upper roller member 150 may be pressed into the material coil 10 together with the lower left and right dies 120 to adjust the length of the inclined portion 11 of the material coil 10 .

[0110] In addition, the upper roller member 150 may be operated in directions approaching or moving away from each other by a fourth motor M4 installed at both ends of the moving bracket 130 .

[0111] The upper roller member 150 includes a support rod 151 and a roller 153 .

[0112] The support rod 151 is installed on the moving bracket 130 , and the roller 153 is rotatably connected to the front end of the support rod 151 .

[0113] In this case, the roller 153 can be rotatably mounted at the front end of the support rod 151 to be in rolling contact with the material coil 10, thereby operating in a state where the material coil 10 is between the roller 153 and the lower left and right molds 120, and determining the length of the inclined portion 11 on the material coil 10, so that the leg 15 connected to the inclined portion 11 can be formed.

[0114] Finally, the first forming machine 100 comprises a cutting component 160 .

[0115] The cutting member 160 may be installed at the rear side of the direction in which the material coil 10 is supplied to the first forming machine 100 .

[0116] The cutting member 160 includes a cutting die 161 and a cutter 163 .

[0117] The cutter 163 is installed to be drivable up and down at an upper side corresponding to the cutting die 161 .

[0118] The cutter 163 may be installed to be drivable up and down by operation of a fifth motor M5 or an air cylinder.

[0119] When the material coil 10 is supplied to the first forming machine 100 in a predetermined length, the cutting part 160 may move the cutter 163 downward to cut the material coil 10 .

[0120] In this case, the cutter 163 is installed to correspond to the front end of the cutting die 161 to cut the material coil 10 .

[0121] The cutting member 160 may be moved in a direction approaching or moving away from the frame F.

[0122] That is, the cutting member 160 is configured to be moved by the fixing block B, and may be moved by the sixth motor M6 connected to the fixing block B.

[0123] Figure 4 and Figure 5 A schematic diagram of a second forming machine applied to a hairpin-type stator coil forming device according to an embodiment of the present invention is shown.

[0124] Reference Figure 4 The second forming machine 200 includes an upper mold 210 and a lower mold 220 , and the second forming machine 200 may be configured in plural according to the shape of a step surface 230 formed on an inner surface of each of the upper mold 210 and the lower mold 220 .

[0125] For example, the shape of the front / rear bent portion 17 varies according to the shape of the step surface 230 of the second forming machine 200, and therefore, upper molds (210a, 210b, 210c, 210d, ...) and lower molds (220a, 220b, 220c, 220d, ...) having different shapes can be provided in plurality so that the forming process can be performed as needed.

[0126] Reference Figure 5 , the material coil 10 loaded in the second forming machine may be loaded in a horizontally placed state so that the inclined portion 11 and the vertex 13 face forward.

[0127] Step surfaces 230 are respectively formed on inner surfaces of the upper mold 210 and the lower mold 220 facing each other.

[0128] The second forming machine 200 is configured so that the apex 13 of the material coil 10 corresponds to the step surface 230 of each of the upper die 210 and the lower die 220 .

[0129] The second forming machine 200 is used to form the material coil 10 so that the one side inclined portion 11 and the other side inclined portion 11 are located on different lines based on the vertex 13 of the material coil 10. That is, the second forming machine 200 is a device for forming the front / rear bent portion 17 by bending a part of the one side inclined portion 11 and a part of the other side inclined portion 11.

[0130] That is, the second molding machine 200 can bend the vertex 13 through the step surface 230 to form the front / rear curved portion 17, and can shape the front / rear curved portion 17 so that one side of the inclined portion is forward or backward than the other side of the inclined portion (refer to Figure 3 direction) positioning.

[0131] Figure 6 A schematic diagram of a third forming machine applied to a hairpin-type stator coil forming device according to an embodiment of the present invention is shown.

[0132] Reference Figure 6 , the material coil 10 may be loaded on the third forming machine 300 in a state in which the inclined portion 11 and the front / rear bent portions 17 are vertical.

[0133] In the present embodiment, the third forming machine 300 and the loaded material coil 10 are shown in a direction viewed from the top to help understand the embodiment of the present invention.

[0134] The third forming machine 300 includes a first clamping member 310 a and a second clamping member 310 b , and both ends of the inclined portion 11 of the material coil 10 conveyed from the conveying jig are loaded to be interposed in the clamping pins 311 of the respective clamping members 310 .

[0135] The clamping pin 311 can be moved in the front-to-back direction (see Figure 1 ) is used to clamp the material coil 10.

[0136] The clamping pins 311 may be moved in directions away from or approaching each other by cylinder operation.

[0137] The clamping member 310 includes a first clamping member 310 a and a second clamping member 310 b that rotates together with a rack 317 rotated by a pinion 315 .

[0138] The first clamping member 310 a is configured to move forward or backward with the center of the rack 317 as a reference through the guide 313 in a state of clamping the one side inclined portion 11 .

[0139] The second clamping member 310 b is configured to rotate together with the rack 317 at the other side of the rack 317 .

[0140] The second clamping member 310 b is configured to rotate in one direction relative to the fixed first clamping member 310 a while clamping the other-side inclined portion 11 .

[0141] That is, the clamping member 310 can rotate to form the inclined portion 11 into a round shape while clamping the corresponding ends of the inclined portion 11 on both sides of the material coil 10 by the clamping pins 311 .

[0142] That is, the material coil 10 may be formed such that the inclined portion 11 may be formed into a circular shape in the front-rear direction by the third forming machine 300 .

[0143] Here, the clamping member 310 may set the bending amount of the inclined portion 11 in the front-rear direction according to the rotation angle of the second clamping member 310 b.

[0144] In other words, the greater the rotation angle of the second clamping member 310b relative to the first clamping member 310a, the greater the degree to which the inclined portion 11 of the material coil 10 is bent in the front-rear direction.

[0145] Here, the transport jig may wait while clamping the material coil 10 until the forming process is completed in the third forming machine 300 .

[0146] Figures 7 to 15 Schematic diagrams of a forming method for forming a stator coil using a hairpin type stator coil forming device according to an embodiment of the present invention are sequentially shown.

[0147] A method of forming the hairpin type stator coil 7 by using the first forming machine 100 as described above is as follows.

[0148] Reference Figure 3 , in a state where the material coil 10 is supported by the lower central die 110 , the material coil 10 is supplied to the first forming machine 100 in a predetermined length.

[0149] Then, refer to Figure 7 , the moving bracket 130 moves downward along the screw 131 by operation of the third motor M3 , and the upper spring member 140 presses the material coil 10 toward the forming surface 111 of the lower central die 110 .

[0150] At the same time, the cutter 163 of the cutting member 160 moves downward by the operation of the fifth motor M5 to cut the material coil 10. The material coil 10 may be fixed by the elastic force of the spring 143.

[0151] In this case, as the upper spring member 140 is pressed into the material coil 10 , the inclined portion 11 and the apex 13 are formed on the material coil 10 along the forming surface 111 of the lower center die 110 .

[0152] Reference Figure 8 , the movable bracket 130 continues to move downward, so that the upper roller member 150 is pressed into the material coil 10 based on the lower left and right molds 120 to form the leg portion 15 connected to the inclined portion 11 on the material coil 10 .

[0153] Here, the lower left-right molds 120 are moved in the left-right direction to be loaded at the setting position.

[0154] That is, the lower left and right dies 120 move in the left and right directions in the mounting groove 113 of the lower central die 110 to adjust the length of the inclined portion 11 of the material coil 10 .

[0155] Reference Fig. 9 As described above, the inclined portion 11, the apex 13 and the leg portion 15 are bent and formed on the material coil 10 by the first forming machine 100, and the material coil 10 is conveyed to the second forming machine 200 by a conveying fixture (not shown).

[0156] Reference Figure 4 The material coil 10 is loaded such that the inclined portion 11 and the vertex 13 of the material coil 10 correspond to between the upper mold 210 and the lower mold 220 of the second forming machine 200 , and more specifically, the vertex 13 corresponds to the corresponding step surfaces 230 of the upper mold 210 and the lower mold 220 .

[0157] Reference Fig.10 The upper die 210 and the lower die 220 are combined to bend the vertex 13 of the material coil 10 into shape through the step surface 230 .

[0158] That is, the front / rear bent portion 17 is formed by bending the vertex 13 so that one of the one side inclined portion 11 and the other side inclined portion 11 is positioned forward or backward, so that the one side inclined portion and the other side inclined portion are located on different lines with the vertex 13 of the material coil 10 as a reference.

[0159] In this case, the conveying jig may wait while clamping the material coil 10 until the forming process is completed in the second forming machine 200 .

[0160] Reference Fig.11 , next, the upper mold 210 and the lower mold 220 are separated.

[0161] The upper mold 210 and the lower mold 220 may be manufactured in a small size corresponding to the size of the material coil 10 , and may be configured to be automatically replaceable when necessary by including various types of the upper mold 210 and the lower mold 220 .

[0162] Reference Fig.12 As described above, the front / rear bent portion 17 is formed on the material coil 10 by the second forming machine 200, and then, the material coil 10 is conveyed to the third forming machine 300 by a conveying jig (not shown).

[0163] Reference Figure 6 , the material coil 10 is loaded so that the front / rear bent portion 17 of the material coil 10 corresponds to between the clamping pins 311 of the third forming machine 300 .

[0164] Reference Fig.13 , the clamping pins 311 move in directions approaching each other to clamp each end of the inclined portion 11 of the material coil 10 .

[0165] Reference Fig.14 As the second clamping member 310b rotates together with the rack 317, the relative angle between the second clamping member 310b and the first clamping member 310a changes.

[0166] Therefore, the inclined portion 11 is formed in a circular shape in the front-rear direction.

[0167] Reference Fig.15 As described above, the third forming machine 300 forms the inclined portion 11 of the material coil 10 into a circular shape in the front-rear direction, thereby finally completing the hair clip stator coil 7 .

[0168] Since the hairpin-type stator coil forming device and forming method according to an embodiment of the present invention can set the length of the inclined portion 11, the angle of the vertex 13 between the inclined portions 11, the degree of curvature of the inclined portion 11, etc. through the first forming machine 100, the second forming machine 200 and the third forming machine 300, stator coils with various shapes can be formed.

[0169] For example, the length of the inclined portion 11 and the angle of the vertex 13 can be adjusted by adjusting the position of the lower left and right molds 120 of the first forming machine 100 in the left and right directions, the degree of bending of the front / rear bending portion 17 can be adjusted by changing the design of the step surface 230 of the upper mold 210 and the lower mold 220 of the second forming machine 200, and the degree of bending of the inclined portion 11 can be set by adjusting the rotation angle of the clamping part 310 of the third forming machine 300.

[0170] In addition, since the hairpin type stator coil forming device and forming method according to an embodiment of the present invention can change the shape of the manufactured stator coil by only changing the setting values ​​input to the first forming machine 100, the second forming machine 200 and the third forming machine 300, productivity can be improved.

[0171] While the invention has been described in connection with what are presently considered to be practical embodiments, it will be understood that the invention is not limited to the disclosed embodiments, but on the contrary, the invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. A hairpin type stator coil forming device, comprising: a first forming machine for causing a central portion of the material coil to protrude upward to form an apex on the material coil, and for forming inclined portions inclined toward both sides of the apex; a second forming machine, on which the material coil bent and formed by the first forming machine is loaded, and a part of the inclined portion on one side and a part of the inclined portion on the other side are bent and formed with the vertex as a reference to form a front / rear bent portion on the material coil; as well as a third forming machine, on which the material coil bent and formed by the second forming machine is loaded, and the inclined portion is formed into a circular shape in the front-rear direction, in, The first forming machine comprises: a lower central die having a forming surface of triangular cross-section; lower left and right dies configured to be slidable in left and right directions on both sides connected to a forming surface of the lower central die and to adjust the length of the inclined portion of the material coil; A movable bracket is supported by a frame at the upper part of the lower central mold and can be moved up and down from the upper part of the frame; an upper spring member which is disposed on both sides of the movable bracket with the center of the forming surface of the lower central die as a reference in a state of being spaced apart from each other by a predetermined distance, and when the movable bracket moves downward, presses the material coil toward the lower central die so that the vertex and the inclined portion are formed on the material coil by the forming surface; and The upper roller component is arranged on both outer sides of the upper spring component through the movable bracket, and the length of the inclined portion is adjusted by pressing the material coil with the lower left and right dies as a reference.

2. The device according to claim 1, wherein: The upper portion of the lower central mold is provided with a forming surface for forming the inclined portion and the vertex on the material coil, and mounting grooves for mounting the lower left and right molds are formed on both sides of the lower central mold.

3. The device according to claim 2, wherein: The lower left and right molds are installed to be slidable in the left and right directions in the installation grooves by operation of a motor.

4. The device according to claim 1, wherein: The moving bracket is mounted on a screw rod rotated by a motor mounted on the frame so as to be movable up and down, and a moving position of the moving bracket is limited by a stopper provided at a lower end portion of the screw rod.

5. The device according to claim 1, wherein: The upper spring component comprises: A spring installed in a snap-fit ​​hole formed on the movable bracket; a spring rod disposed inside the spring and installed to pass through an upper portion of the frame; and A spring block is connected to one end of the spring rod and is molded into the material coil toward the lower center as the movable bracket moves downward.

6. The device according to claim 1, wherein: The upper roller component comprises: A support rod mounted on the mobile support; and The roller is rotatably mounted on the front end of the support rod, and as the movable bracket moves downward, the material coil is bent toward the lower left and right molds and pressed into the material coil toward the lower left and right molds.

7. The device according to claim 1, wherein: The first forming machine further comprises: a cutting member installed at the rear side of the direction in which the material coil is supplied and cuts the material coil at a set length, The cutting component comprises: a cutting die disposed below the material coil; and The cutter is arranged on the upper side corresponding to the cutting die and driven in the up-down direction.

8. The device according to claim 1, wherein: The second forming machine includes an upper die and a lower die, the apex and the inclined portion of the material coil formed by the first forming machine are between the upper die and the lower die, and Step surfaces are respectively formed on inner surfaces of the upper mold and the lower mold facing each other, and the apex is shaped to form the front / rear bent portion so that the inclined portions are respectively located on different lines with the apex of the material coil as a reference.

9. The device according to claim 1, wherein: The third forming machine comprises: The clamping parts are respectively provided corresponding to both ends of the inclined portion of the material coil formed by the second forming machine so that the inclined portion is clamped by a clamping pin.

10. The device according to claim 9, wherein: The clamping member comprises: A first clamping member, which can move forward and backward with the center of the rack as a reference through a guide member while clamping the inclined portion on one side; and The second clamping member is installed to rotate together with the rack rotated by the pinion gear, and rotates in one direction relative to the first clamping member while clamping the other side inclined portion.

11. The device according to claim 10, wherein: The clamping member is configured to rotate in a state where the material coil is clamped by the clamping pin to adjust a rounded angle of the inclined surface.

12. A method for forming a hairpin stator coil performed by the apparatus according to any one of claims 1 to 11, comprising: cutting coils of material at predetermined lengths; forming a vertex and a slope on the coil of material; Loading the vertex and the inclined portion so that the vertex and the inclined portion are between an upper mold and a lower mold; The apex is formed into a front / rear curved portion by combining the upper mold and the lower mold so that the inclined portions are located on different lines with respect to the apex; loading the end of the inclined portion so that the end of the inclined portion is between the clamping pins; as well as The clamping member is rotated so that the inclined portion is formed into a circular shape in the front-rear direction.

13. The method according to claim 12, wherein: Cutting material coils and forming apexes and bevels include: Allowing the material coil to enter the upper portion of the lower central die; cutting the material coil by a cutting member disposed at a rear side in an entry direction of the material coil; Moving the movable bracket downwardly so that the upper spring member presses the material coil toward the forming surface of the lower central die, thereby forming the apex and the inclined portion on the material coil along the forming surface; and The movable bracket is made to continue to move downward, so that the upper roller component is molded into the material coil along the lower left and right sides.

14. The method according to claim 13, wherein: Forming apex and bevel sections includes: When the upper roller member moves downward to press the material coil toward the lower left and right dies, the lower left and right dies are moved in the left-right direction to be loaded at a predetermined position.

15. The method according to claim 12, wherein: Loading the apex and the inclined portion comprises: loading the material coil so that the apex and the inclined portion are between the upper die and the lower die, and Shaping the apex into a front / back bend comprises: The apex is formed into the front / rear curved portion by combining the upper mold and the lower mold so that the inclined portions are located on different lines with respect to the apex.

16. The method according to claim 12, wherein: The end portion for loading the inclined portion comprises: loading the material coil so that the end of the inclined portion is between the clamping pins, The clamping member comprises a first clamping member and a second clamping member, The rotating clamping parts include: In a state where the material coil is clamped by the clamp pin, the second clamping member is rotated in one direction relative to the first clamping member, so that the inclined portion of the material coil is formed into a circular shape in the front-rear direction.

17. The method according to claim 16, wherein: The first clamping member is driven along the guide in a direction approaching or moving away from the second clamping member.

18. The method according to claim 16, wherein: The bending amount of the inclined portion in the front-rear direction is determined according to the rotation angle of the second clamping member.

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