An embedded copper busbar wave winding coil forming device

Abstract

The present invention provides an embedded copper busbar wave winding coil forming device, including an end forming device and a straight edge bending device, the end forming device includes an end clamping device, an end top arc device, and a straight edge clamping device, and the end ends of the coil are sequentially connected from the outside to the inside with the end clamping device, the end top arc device, and the straight edge clamping device, and the straight edge bending device is arranged between the straight edge clamping devices. The present invention has the advantages of consistent shape, accurate size, precise coil span, stable and reliable product quality, reduced labor intensity, improved production efficiency, shortened process time, and reduced manufacturing cost.

Description

Technical Field

[0001] The invention relates to a motor coil forming process, and in particular to an embedded copper busbar wave winding coil forming device. Background Art

[0002] In YR wound-rotor motors, the rotor winding usually adopts a wave winding structure. When the three-phase coil is connected in star shape and the neutral point and the phase lead-out line are not at the same end, a layer-lifting coil (also called a layer-skipping coil) is used to realize the inter-pole series connection in each phase. The forming methods of the wave winding copper busbar coil include manual knocking, mold knocking and equipment forming. The manual method has a narrow scope of application and generally does not have insulation pre-forming. The other end of the plug-in structure needs to be knocked on the core with a simple tool. Due to the limitation of the operating space, the shape consistency of the end arc is difficult to ensure, and it is easy to damage the insulation, the size is inaccurate, and the end is not flush; although the mold knocking can ensure the shape of the end arc in the embedded structure (the groove shape is an open groove or a semi-open groove), the shape consistency is poor, the size is inaccurate, and the end is not flush due to inaccurate positioning when the end angle is bent; both manual knocking and mold knocking have the disadvantages of large original rotor imbalance, high labor intensity, and low production efficiency. The equipment forming method has good shape consistency and accurate size in the embedded structure (the groove shape is an open groove or a semi-open groove), does not need to add an end leveling process, and has the advantages of low labor intensity, high production efficiency, and low manufacturing cost.

[0003] In the embedded structure, the quality of the end arc of the copper busbar depends on the design method of the mold and the appropriate process method. The traditional process method is difficult to achieve satisfactory results such as reliable forming quality, low labor intensity, high production efficiency and low manufacturing cost.

[0004] Therefore, it is necessary to provide a new technical solution. Summary of the invention

[0005] In order to solve the technical problems existing in the prior art, the present invention discloses an embedded copper busbar wave winding coil forming device, and the specific technical scheme is as follows:

[0006] The present invention provides an embedded copper busbar wave winding coil forming device, comprising an end forming device and a straight edge bending device, wherein the end forming device is arranged at both ends of the coil, and the straight edge bending device is arranged between the end forming devices.

[0007] The straight edge bending device comprises a platform bottom plate, a positioning plate, a fixing pin and a bending wrench.

[0008] The positioning plates are fixed to the platform bottom plate by bolts, and coils are passed between the positioning plates.

[0009] The bending wrench is connected to the platform bottom plate through a bolt pivot, and the bending wrench is respectively fixed on both sides of the coil, and the bending wrench on one side rotates circumferentially along the bolt connection point to bend the coil, and the fixing pin is inserted into the edge of the bending wrench to fix the bending wrench, and the bending wrench on the other side continues to bend the coil along the bent coil, and the coil after bending again is parallel to the coil passing through the positioning plate.

[0010] Furthermore, the bending radius of the coil on the straight edge bending device is not less than 3 times the thickness of the copper busbar.

[0011] Furthermore, the end forming device includes an end clamping device, an end top arc device, and a straight edge clamping device.

[0012] The two ends of the coil are connected with an end clamping device, an end top arc device, and a straight edge clamping device in sequence from outside to inside, and the straight edge bending device is arranged between the straight edge clamping devices.

[0013] Furthermore, the end clamping device comprises a first top block, a clamping block and a first support plate.

[0014] The first top blocks are arranged relatively to each other, and mounting grooves are respectively arranged on the opposite surfaces of the first top blocks, and clamping blocks are arranged in the mounting grooves. The ends of the clamping blocks are arranged as hemispherical convex point structures, and the coils are clamped between the clamping blocks. The first support plate extends into the first top blocks to support the coils, and the first support plate is arranged to be movable along the thickness direction of the coils.

[0015] Furthermore, the end top arc device includes a clamping plate, a top arc plate and an adjusting shaft.

[0016] The clamping plates are arranged opposite to each other, and threaded holes are arranged on the clamping plates, and the clamping plates are connected and fixed through the threaded holes;

[0017] The top arc plate is fixed between the clamping plates, the arc portion at one end of the top arc plate is set to an elliptical cylinder surface shape, the top arc plate is provided with a through hole, the through hole corresponds to the threaded hole on the clamping plate, and the other end of the top arc plate is connected and fixed to the adjustment shaft;

[0018] The adjusting shaft is cylindrical and can rotate circumferentially. A flat-bottom groove is arranged on the top of the adjusting shaft. The width of the flat-bottom groove matches the thickness of the top arc plate. The other end of the top arc plate is inserted into the flat-bottom groove. The top arc plate is fixed to the adjusting shaft.

[0019] Furthermore, the straight edge clamping device comprises a second top block and a second support plate,

[0020] The second top blocks are arranged opposite to each other, the coil is clamped between the second top blocks, the second supporting plate extends into between the second top blocks to support the coil, and the second supporting plate is arranged to be movable along the thickness direction of the coil.

[0021] Furthermore, the surfaces of the end forming device and the straight edge bending device are plated with nickel or chromium.

[0022] The present invention has the following beneficial effects:

[0023] 1. The embedded copper busbar wave winding coil forming device provided by the present invention can achieve the requirements of uniform shape, accurate size, precise coil span, and neat end faces of both ends of each coil after wire embedding.

[0024] 2. The embedded copper busbar wave winding coil forming device provided by the present invention is suitable for mass production, and the product quality is stable and reliable.

[0025] 3. The embedded copper busbar wave winding coil forming device provided by the present invention can greatly reduce labor intensity, improve production efficiency, shorten process time and reduce manufacturing cost.

[0026] 4. The embedded copper busbar wave winding coil forming device provided by the present invention has good quality stability and economic benefits.

[0027] Additional aspects and advantages of the present invention will be given in part in the following description and in part will be obvious from the following description, or will be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0029] Figure 1 A schematic structural diagram of an end forming device in an embedded copper busbar wave winding coil forming device provided in an embodiment of the present invention.

[0030] Figure 2 A schematic structural diagram of a straight edge bending device in an embedded copper busbar wave winding coil forming device provided in an embodiment of the present invention.

[0031] Figure 3 for Figure 1 Schematic diagram of the structure of the middle end clamping device.

[0032] Figure 4 for Figure 1Schematic diagram of the structure of the middle end top arc device.

[0033] Figure 5 for Figure 1 Schematic diagram of the structure of the straight edge clamping device.

[0034] Among them, 1-end forming device, 2-straight edge bending device, 11-end clamping device, 12-end top arc device, 13-straight edge clamping device, 21-platform bottom plate, 22-positioning plate, 23-fixing pin, 24-bending wrench, 111-first top block, 112-clamping block, 113-first support plate, 121-clamping plate, 122-top arc plate, 123-adjusting shaft, 131-second top block and 132-second support plate. DETAILED DESCRIPTION

[0035] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be construed as limiting the present invention.

[0036] In the description of the present invention, it should be understood that the terms "upper", "lower", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In the description of the present invention, "plurality" means two or more, unless otherwise clearly and specifically defined.

[0037] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0038] The present invention provides an embedded copper busbar wave winding coil forming device, referring to Figures 1 to 4 , including an end forming device 1 and a straight edge bending device 2, the end forming device 1 is arranged at both ends of the coil, and the straight edge bending device 2 is arranged between the end forming devices 1.

[0039] The straight edge bending device 2 includes a platform bottom plate 21, a positioning plate 22, a fixing pin 23 and a bending wrench 24. The positioning plate 22 is fixed to the platform bottom plate 21 by bolts, and a coil is passed between the positioning plates 22. The bending wrench 24 is pivotally connected to the platform bottom plate 21 by bolts, and the bending wrench 24 is fixed to both sides of the coil respectively, wherein the bending wrench 24 on one side rotates circumferentially along the bolt connection point to bend the coil, the fixing pin 23 is inserted into the edge of the bending wrench 24 to fix the bending wrench 24, and the bending wrench 24 on the other side continues to bend the coil along the bent coil, and the coil after bending again is parallel to the coil passing through the positioning plate 22.

[0040] In one embodiment, the bending radius of the coil on the straight edge bending device 2 is not less than 3 times the thickness of the copper busbar.

[0041] The end forming device 1 comprises an end clamping device 11, an end top arc device 12, and a straight edge clamping device 13. The end portions of the coil are sequentially connected from outside to inside with the end clamping device 11, the end top arc device 12, and the straight edge clamping device 13, and the straight edge bending device 2 is arranged between the straight edge clamping devices 13.

[0042] The end clamping device 11 includes a first top block 111 , a clamping block 112 and a first supporting plate 113 .

[0043] The first top blocks 111 are arranged opposite to each other, and mounting grooves are arranged on the opposite surfaces of the first top blocks 111, and clamping blocks 112 are arranged in the mounting grooves. The ends of the clamping blocks 112 are arranged as hemispherical convex point structures, and the coils are clamped between the clamping blocks 112. The first supporting plate 113 extends into the first top blocks 111 to support the coils, and the first supporting plate 113 is arranged to be movable along the thickness direction of the coils.

[0044] The end top arc device 12 comprises a clamping plate 121, a top arc plate 122 and an adjustment shaft 123. The clamping plates 121 are arranged opposite to each other, and a threaded hole is arranged on the clamping plate 121, and the clamping plate 121 is connected and fixed through the threaded hole; the top arc plate 122 is fixed between the clamping plates 121, and the arc portion at one end of the top arc plate 122 is set to be an elliptical cylinder surface shape, and a through hole is arranged on the top arc plate 122, and the through hole corresponds to the threaded hole on the clamping plate 121, and the other end of the top arc plate 122 is connected and fixed to the adjustment shaft 123; the adjustment shaft 123 is cylindrical and can rotate in the circumferential direction, and a flat bottom groove is arranged on the top of the adjustment shaft 123, and the width of the flat bottom groove matches the thickness of the top arc plate 122, and the other end of the top arc plate 122 is inserted into the flat bottom groove, and the top arc plate 122 is fixed to the adjustment shaft 123.

[0045] The straight edge clamping device 13 comprises a second top block 131 and a second support plate 132. The second top blocks 131 are arranged opposite to each other, the coil is clamped between the second top blocks 131, the second support plate 132 extends into the second top blocks 131 to support the coil, and the second support plate 132 is arranged to be movable along the thickness direction of the coil.

[0046] In one embodiment, the surfaces of the end forming device 1 and the straight edge bending device 2 are plated with nickel or chromium for rust prevention.

[0047] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example" or "some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine different embodiments or examples described in this specification.

[0048] Although the embodiments of the present invention have been shown and described above, it is to be understood that the above embodiments are exemplary and are not to be construed as limitations of the present invention. A person skilled in the art may change, modify and vary the above embodiments within the scope of the present invention.

Claims

1. An embedded copper busbar wave winding coil forming device, characterized in that: It includes an end forming device and a straight edge bending device, wherein the end forming device is arranged at both ends of the coil, and the straight edge bending device is arranged between the end forming devices. The straight edge bending device comprises a platform bottom plate, a positioning plate, a fixing pin and a bending wrench. The positioning plate is fixed to the platform bottom plate by bolts, and a coil is passed between the positioning plates. The bending wrench is connected to the platform bottom plate through a bolt pivot, and the bending wrench is fixed to both sides of the coil respectively. The bending wrench on one side is rotated circumferentially along the bolt connection point to bend the coil, and the fixing pin is inserted into the edge of the bending wrench to fix the bending wrench. The bending wrench on the other side continues to bend the coil along the bent coil, and the coil after being bent again is parallel to the coil passing through the positioning plate. The end forming device includes an end clamping device, an end top arc device, and a straight edge clamping device. The two ends of the coil are connected with an end clamping device, an end top arc device, and a straight edge clamping device in sequence from outside to inside, and the straight edge bending device is arranged between the straight edge clamping devices.

2. The embedded copper busbar wave winding coil forming device according to claim 1 is characterized in that: The bending radius of the coil on the straight edge bending device is not less than 3 times the thickness of the copper busbar.

3. The embedded copper busbar wave winding coil forming device according to claim 1 is characterized in that: The end clamping device comprises a first top block, a clamping block and a first support plate, The first top blocks are arranged opposite to each other, and mounting grooves are arranged on the opposite surfaces of the first top blocks respectively. A clamping block is arranged in the installation groove, and the end of the clamping block is arranged as a hemispherical convex point structure. The coil is clamped between the clamping blocks, and the first supporting plate extends into between the first top blocks to support the coil. The first supporting plate is arranged to be movable along the thickness direction of the coil.

4. The embedded copper busbar wave winding coil forming device according to claim 1 is characterized in that: The end top arc device comprises a clamping plate, a top arc plate and an adjusting shaft. The clamping plates are arranged opposite to each other, and threaded holes are arranged on the clamping plates, and the clamping plates are connected and fixed through the threaded holes; The top arc plate is fixed between the clamping plates, the arc portion at one end of the top arc plate is set to an elliptical cylinder surface shape, the top arc plate is provided with a through hole, the through hole corresponds to the threaded hole on the clamping plate, and the other end of the top arc plate is connected and fixed to the adjustment shaft; The adjusting shaft is cylindrical and can rotate in the circumferential direction. A flat bottom groove is arranged on the top of the adjusting shaft. The width of the flat bottom groove matches the thickness of the top arc plate, the other end of the top arc plate is inserted into the flat bottom groove, and the top arc plate is fixed to the adjustment shaft.

5. The embedded copper busbar wave winding coil forming device according to claim 1 is characterized in that: The straight edge clamping device comprises a second top block and a second support plate, The second top blocks are arranged opposite to each other, the coil is clamped between the second top blocks, the second supporting plate extends into the space between the second top blocks to support the coil, and the second supporting plate is arranged to be movable along the thickness direction of the coil.

6. The embedded copper busbar wave winding coil forming device according to claim 1 is characterized in that: The surfaces of the end forming device and the straight edge bending device are plated with nickel or chromium.

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