Coil bending device for hairpin stator coil forming system for drive motors

Abstract

The present invention discloses a coil bending device for a hairpin type stator coil forming system, the device comprising: a tubular nozzle, which is arranged to pass through the horizontal central part of a shell and supply material coils through the tubular nozzle; a nozzle moving device, which moves the nozzle in one direction; a bending device, which comprises a pair of roller members on the upper surface of a rotating member, and clamps the material coil discharged from the nozzle between the pair of roller members to bend the material coil into a set shape; a horizontal moving device, which is used to horizontally move the bending device through a first plate slidably mounted on the shell; a vertical moving device, which is used to vertically move the bending device through a second plate slidably mounted on the first plate; a first rotating device, which is used to rotate the bending device with a horizontal axis as a reference through a third plate rotatably mounted on the second plate; and a second rotating device, which is used to rotate the bending device with a vertical axis as a reference through a planetary gear mounted on the second plate.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of Korean Patent Application No. 10-2019-0166728 filed in the Korean Intellectual Property Office on December 13, 2019, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates to a coil bending device for a hairpin type stator coil forming system. More specifically, the present disclosure relates to a coil bending device for a hairpin type stator coil forming system that can improve process flexibility by separately controlling the positions of a nozzle and a bending device that are in direct contact with a material coil and can be applied regardless of the shape and type of the stator coil. 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 force from electric energy.

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

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

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

[0008] A driving motor of a permanent magnet synchronous motor used as a power source of an environmentally friendly vehicle basically includes a stator generating magnetic flux, a rotor provided with a predetermined gap from the stator and performing a rotational motion, and a permanent magnet mounted on the rotor.

[0009] Here, the stator has a plurality of slots formed on an inner peripheral side of a stator core, and stator coils are wound in the slots.

[0010] Therefore, when an alternating current is applied to the stator coil, a rotating magnetic field is generated in the stator, and a rotational 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, wherein the stator of the distributed winding type drive motor can be divided into a segmented coil stator and a distributed winding coil stator according to the coil winding method.

[0012] In this case, the segment coil stator is a stator in which the coil is preliminarily formed into a predetermined shape and then inserted into the slot of the stator core. In addition, the distributed winding coil stator is a stator in which the coil bundle is inserted into the slot of the 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 sizes of the stator core and the drive motor inevitably increase, which makes it difficult to reduce the size of the drive motor.

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

[0016] In other words, a method of minimizing a dead space between a stator core and a wound coil or a dead space between each coil to increase the coil area may be considered.

[0017] Under such circumstances, in order to replace the use of a toroidal coil having a circular cross section (also referred to as a "circular coil" in the art) as a coil winding, a flat coil (also referred to as a "square coil" in the art) has also been actively sought in recent years.

[0018] In the case of a flat coil, due to the cross-sectional shape, it is possible to reduce dead space and increase slot fill rate compared to a toroidal coil.

[0019] However, in the case of a flat coil, the coil winding work is relatively difficult compared to a toroidal coil.

[0020] This is because, in the case of a flat coil, since the rigidity increases due to the fact that the flat coil is manufactured with a larger cross-sectional area than a toroidal coil in order to maximize the slot fill rate, it is difficult to use a winding machine.

[0021] Therefore, the following method has been proposed as a method for facilitating the coil winding work of the square coil in the segmented coil stator of the distributed winding type drive motor. That is, 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 the stator core. Then, the stator coils adjacent in the radial direction in the slots are welded. Then, a continuous coil winding of the stator core is formed.

[0022] A drive motor having a hairpin winding type stator manufactured in this way is also referred to in the art as a "hairpin drive motor".

[0023] By using the stator coil winding structure of the hairpin type drive motor, the limitation caused by the winding machine is overcome, and the coil winding operation is relatively easy even in the case of a square coil. In addition, the coil slot full rate can be increased and a high-output and miniaturized motor can be realized.

[0024] On the other hand, in the forming process of the hairpin type stator coil as described above, the forming process can be roughly divided into a CNC (computer numerical control) forming method and a stamping forming method, but there are multiple types of hairpins in a hairpin type drive motor, so it is advantageous to have a CNC forming method that can cope with multiple types.

[0025] However, in the CNC forming method capable of coping with various types according to the prior art, the production speed of one hairpin is about 6 seconds, so the production speed is somewhat slow. Compared with the CNC forming method, the stamping forming method has twice the productivity, but has the disadvantage of only being able to 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 present disclosure and therefore it may contain information that does not form the prior art that is already known to a person of ordinary skill in the art. Summary of the invention

[0028] The exemplary embodiment of the present disclosure improves process flexibility by controlling the individual positions of the nozzle and the bending device for forming the material coil, and also simplifies the structure for controlling the positions of the nozzle and the bending device. The exemplary embodiment of the present disclosure aims to provide a coil bending device for a hairpin type stator coil forming system that can be applied regardless of the shape and type of the stator coil, thereby reducing investment and process costs.

[0029] According to one or more exemplary embodiments of the present disclosure, a coil bending device for a hairpin-type stator coil forming system bends a square material coil into a set shape, and the coil bending device includes: a tubular nozzle, which is arranged to pass through the horizontal central part of a shell, and supplies the material coil through the inside of the tubular nozzle; a nozzle moving device, which is connected to one end of the nozzle to move the nozzle in one direction; a bending device, including a pair of roller members on the upper surface of a rotating member arranged corresponding to the other end of the nozzle, and the material coil discharged from the nozzle is clamped between the pair of roller members to bend the material coil into a set shape; a horizontal moving device, which is used to move the bending device in the horizontal direction through a first plate slidably mounted on the shell; a vertical moving device, which is used to move the bending device in the vertical direction through a second plate slidably mounted on the first plate; a first rotating device, which is used to rotate the bending device with a horizontal axis as a reference through a third plate rotatably mounted on the second plate; and a second rotating device, which is used to rotate the bending device with a vertical axis as a reference through the operation of a planetary gear mounted on the second plate.

[0030] Furthermore, the nozzle may have a cylindrical shape with a hollow interior to supply the material coil through the interior of the nozzle.

[0031] In addition, the nozzle moving device may include: a moving device bracket, which is arranged on the front side of the shell; a moving device actuator, which is installed on the moving device bracket; and a connecting bracket, which is installed between the driving shaft of the moving device actuator and the front end of the nozzle and is configured to enable the nozzle to slide back and forth along the connecting guide rail on the moving device bracket.

[0032] In addition, the bending device may include: a rotating member that rotates with a vertical axis as a reference; a rotating member shell that surrounds a predetermined portion of the rotating member; and a pair of roller members that are installed on the upper surface of the rotating member protruding a predetermined portion from the rotating member shell, are arranged corresponding to the outlet of the nozzle that discharges the material coil, and clamp the material coil between the pair of roller members to bend the material coil into a set shape.

[0033] In addition, the horizontal moving device may include: a first plate, which is arranged at the rear of the shell and is slidably mounted on the shell through upper and lower guide rails; and a first actuator, which is mounted on the shell and connected to the first plate through a fixed block mounted on the front end of the driving shaft, and moves the first plate in the horizontal direction.

[0034] In addition, the vertical moving device may include: a second plate, which is arranged on the rear side of the first plate and is slidably mounted on the first plate through left and right guide rails; and a second actuator, which is arranged on the upper side of the shell and is connected to the second plate through a mounting bracket to move the second plate in the vertical direction.

[0035] In addition, the vertical moving device may further include: an auxiliary cylinder connected between the housing and the mounting bracket and applying a driving force to the second plate together with the second actuator.

[0036] In addition, the first rotating device may include: a disc-shaped third plate rotatably mounted to the central portion of the second plate; a rotating device housing, one end of which is connected to a rotating member housing surrounding the rotating member, and the other end of which is connected to the third plate to rotate the bending device with the horizontal axis as a reference through the rotation of the third plate; a third actuator installed through a mounting bracket of the vertical moving device and having a first driving gear formed at the front end; and a first driven gear meshed with the first driving gear and connected to the rear side of the third plate to rotate together with the third plate through the first driving gear as the third actuator operates.

[0037] In addition, as the third actuator operates, the first driven gear meshing with the first driving gear, the third plate coupled to the first driven gear, the rotating device housing coupled to the third plate, and the rotating member housing can rotate so that the bending device moves with the horizontal axis as the reference.

[0038] Furthermore, the first driving gear and the first driven gear may be planetary gears having different gear diameters.

[0039] In addition, the second rotating device may include: a horizontal driving unit, which is arranged inside the rotating device housing, one end of the horizontal driving unit passes through the rotating member housing and is connected to the rotating member, and a secondary driven gear is arranged at the other end of the horizontal driving unit; a fourth actuator, which is installed through a mounting bracket and has a second driving gear formed at the front end; a second driven gear, which is meshed with the second driving gear and is arranged in front of the first driven gear; and a connecting driven gear, which is formed behind the second driven gear and has a diameter smaller than that of the second driven gear, is formed integrally with the second driven gear, and is meshed with the secondary driven gear while passing through the interior of the first driven gear.

[0040] In addition, the second rotating device can be configured to rotate the bending device with the vertical axis as the reference, while the horizontal driving unit rotates through the second driven gear meshing with the second driving gear, the connecting driven gear formed integrally with the second driven gear, and the auxiliary driven gear meshing with the connecting driven gear as the fourth actuator is operated.

[0041] In addition, the second driving gear, the second driven gear, the counter driven gear, and the connecting driven gear may be planetary gears having different gear diameters.

[0042] Compared with the existing stamping forming method, the coil bending device for the hairpin type stator coil forming system according to the exemplary embodiment of the present disclosure can improve process flexibility through the separate position control of the nozzle and the bending device for forming the material coil.

[0043] In addition, the coil bending device for a hairpin type stator coil forming system according to an exemplary embodiment of the present disclosure simplifies the structure for controlling the position of the nozzle and the bending device, and can be applied regardless of the shape and type of the stator coil, thereby reducing investment and process costs.

[0044] In addition, the effects obtained or predicted by the embodiments of the present disclosure will be disclosed directly or implicitly in the detailed description of the embodiments of the present disclosure. That is, various effects predicted according to the embodiments of the present disclosure will be disclosed in the detailed description described below. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 is a view schematically showing the structure of a hairpin winding type stator applied to a drive motor according to an embodiment of the present disclosure.

[0046] Figure 2 is a view showing a hairpin type stator coil forming system applied to an embodiment of the present disclosure.

[0047] Figure 3 is a perspective view of a coil bending device for a hairpin-type stator coil forming system according to an embodiment of the present disclosure.

[0048] Figure 4 is a structural diagram showing a nozzle moving device of a coil bending device for a hairpin type stator coil forming system applied to an embodiment of the present disclosure.

[0049] Figure 5 is a structural diagram showing a bending device of a coil bending device applied to a hairpin type stator coil forming system according to an embodiment of the present disclosure.

[0050] Figure 6 is a structural diagram showing a horizontal moving device of a coil bending device for a hairpin type stator coil forming system applied to an embodiment of the present disclosure.

[0051] Figure 7 is a structural diagram showing a vertical moving device of a coil bending device for a hairpin-type stator coil forming system applied to an embodiment of the present disclosure.

[0052] Figure 8 is a structural diagram showing a first rotating device of a coil bending device for a hairpin-type stator coil forming system according to an embodiment of the present disclosure.

[0053] Fig. 9 is a structural diagram illustrating a second rotating device applied to a coil bending device for a hairpin-type stator coil forming system according to an embodiment of the present disclosure.

[0054] Fig.10 is a structural diagram illustrating connection between a second rotating device and a bending device of a coil bending device for a hairpin-type stator coil forming system according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0055] Hereinafter, the present disclosure will be described more fully with reference to the accompanying drawings, in which exemplary embodiments of the present disclosure are shown. As those skilled in the art will appreciate, the described embodiments may be modified in various different ways without departing from the spirit or scope of the present disclosure.

[0056] In order to clearly describe the present disclosure, parts irrelevant to the description are omitted, and the same reference numerals are applied to the same or similar elements throughout the specification.

[0057] In the following description, since the names of components are the same as each other, the names of the components are distinguished as first, second, etc. for distinguishing the names, and the order thereof is not particularly limited.

[0058] Figure 1 is a view schematically showing the structure of a hairpin winding type stator applied to a drive motor according to an embodiment of the present disclosure.

[0059] Reference Figure 1 The hairpin winding type stator 1 applied to the driving motor of the exemplary embodiment of the present disclosure may be applied to a driving motor of a hybrid vehicle and / or an electric vehicle which is an environmentally friendly vehicle that obtains driving force using electric energy.

[0060] For example, the drive motor may use a permanent magnet synchronous motor (PMSM).

[0061] The driving motor includes a stator 1 according to an embodiment of the present disclosure, a rotor (not shown) disposed with a gap apart from the stator 1 , and a plurality of permanent magnets (not shown) mounted on the rotor.

[0062] On the above, the stator 1 includes a stator core 3 of which a plurality of electric steel plates are stacked. A hairpin type stator coil 7 (generally referred to as a "conductor" in the art) is wound on the stator core 3 through a plurality of slots 5.

[0063] In addition, the rotor includes a rotor core in which a plurality of electrical steel sheets are stacked in an axial direction.

[0064] The above-mentioned permanent magnets are inserted and mounted in insertion holes provided in the rotor core.

[0065] Here, the driving motor may use an inner rotor type synchronous motor in which a rotor is provided inside the stator 1 , or may use an outer rotor type synchronous motor in which a rotor is provided outside the stator 1 .

[0066] As described above, the hairpin type stator coil 7 is a flat coil, for example, having a pair of legs and arranged in a U-shaped or V-shaped hairpin shape as a whole, and may be provided as a square coil having a square cross section.

[0067] These hairpin type stator coils 7 are inserted into the fixed layer (indicated by dotted lines in the figure) of the slots 5 in the stator core 3 and the ends of a pair of legs protrude outside the slots 5, and the protruding parts can be welded to form an electrically connected coil winding.

[0068] Although the embodiments of the present disclosure are described as applying a hairpin winding type to a stator in a drive motor used in an environmentally friendly vehicle as described above, the scope of protection of the present disclosure should not be understood as being limited to this, and the technical ideas of the present disclosure can be applied to drive motors having hairpin stators for various types and uses.

[0069] Figure 2 is a view showing a hairpin type stator coil forming system applied to an embodiment of the present disclosure.

[0070] Reference Figure 2 The coil supply device 107 according to the exemplary embodiment of the present disclosure can be applied to a stator 1 having a hairpin winding as described above (see Figure 1 ) is a coil forming system 200 for forming a hairpin-type stator coil 7 in the assembly process of a drive motor.

[0071] The coil forming system 200 according to the example includes a coil unwinder 101 , a coil straightener 103 , a coil supply device 107 , and a coil bending device 100 .

[0072] The coil forming system 200 unwinds the square material coil 9 wound on the coil unwinder 101 and flattens the material coil 9 through the coil straightener 103. The flattened material coil 9 may be supplied to the coil bending device 100 through the coil supply device 107.

[0073] Here, the coil straightener 103 flattens the material coil 9 by means of the flattening roller 105 , so that the material coil 9 can be straightened in the vertical / horizontal direction.

[0074] The coil supply device 107 is used to transfer the material coil 9 to be bent into shape by the coil bending device 100 according to the exemplary embodiment of the present disclosure to the coil bending device 100 along a set path.

[0075] That is, the coil supply device 107 is used to transfer the supplied material coil 9 along the traveling direction.

[0076] The coil supply device 107 is mounted on a base frame (not shown in the figure), and is arranged between the coil straightener 103 and the coil bending device 100 along the front-rear direction on the base frame.

[0077] Also, the coil bending device 100 according to the exemplary embodiment of the present disclosure may bend the material coil 9 transferred by the coil supply device 107 into a set shape.

[0078] Hereinafter, the coil unwinder 101 side is defined as the front side, the coil bending device 100 side is defined as the rear side, and the front-to-back direction is set as the reference direction. Then, the upward portion is defined as the upper portion, the upper end, the upper surface, and the upper end portion, and the downward portion is defined as the lower portion, the lower end, the lower surface, and the lower end portion.

[0079] That is, the moving direction of the material coil 9 is defined as moving from the front to the back.

[0080] Furthermore, in the following, an end (one side / one side end or the other side / the other side end) may be defined as either end or a portion including the end (one side / one side end or the other side / the other side end).

[0081] Figure 3 is a perspective view of a coil bending device for a hairpin-type stator coil forming system according to an embodiment of the present disclosure. Figure 4 is a structural diagram showing a nozzle moving device of a coil bending device for a hairpin type stator coil forming system applied to an embodiment of the present disclosure.

[0082] Reference Figure 3 In an exemplary embodiment of the present disclosure, the coil bending device 100 includes a nozzle 20, a nozzle moving device 30 for moving the nozzle 20, a bending device 40, a horizontal moving device 50 for moving the bending device 40, a vertical moving device 60, a first rotating device 70 and a second rotating device 80.

[0083] The coil bending device 100 is composed of a structure in which all components are mounted on a rectangular housing 10 .

[0084] The housing 10 has open front and rear surfaces, a partition plate 11 formed in the housing 10 , and a first through hole 13 formed in the partition plate 11 .

[0085] The cover 15 is mounted on the rear surface of the housing 10 .

[0086] In addition, the nozzle 20 is provided to pass through the central portion of the housing 10 in the horizontal direction.

[0087] The nozzle 20 has a tubular shape with a hollow interior so as to supply the material coil 9 through the interior of the nozzle 20 .

[0088] In addition, the nozzle 20 may be provided with a cutting knife (not shown) at its rear end to cut the material coil 9 that has been bent into shape.

[0089] The front end of the nozzle 20 is fitted to and supported by the diaphragm 11 .

[0090] Reference Figure 4 In an exemplary embodiment of the present disclosure, the nozzle moving device 30 is disposed at the front side of the nozzle 20 and is configured to move the nozzle 20 in the front-rear direction.

[0091] The nozzle moving device 30 includes a moving device bracket 33 mounted on the partition plate 11 at the front side of the housing 10 .

[0092] A moving device actuator 31 for actuating the moving device is mounted on a moving device bracket 33 .

[0093] In addition, the connection bracket 35 is installed on the driving shaft 311 of the moving device actuator 31. The connection bracket 35 connects the nozzle 20 and the driving shaft 311, and is slidably installed on the moving device bracket 33 through the connection guide 37.

[0094] For example, the drive shaft 311 of the moving device actuator 31 may be formed as a linear guide.

[0095] The nozzle moving device 30 is configured to change the front and rear position of the nozzle 20 while a connection bracket 35 connected to a driving shaft 311 of the moving device actuator 31 moves along the moving device bracket 33 through a connection guide 37 by operation of the moving device actuator 31 .

[0096] Figure 5 is a structural diagram showing a bending device of a coil bending device applied to a hairpin type stator coil forming system according to an embodiment of the present disclosure.

[0097] Reference Figure 5 In an exemplary embodiment of the present disclosure, the bending device 40 is installed at the outside of the housing 10 and is configured to correspond to the rear end of the nozzle 20 .

[0098] The bending device 40 includes a rotating member 41 that rotates with a vertical axis V as a reference, and a pair of roller members 45 mounted on an upper surface of the rotating member 41 .

[0099] At this time, the rotating member 41 rotates with respect to the rotating member case 43 about the vertical axis V in a state in which a predetermined lower portion of the rotating member 41 is surrounded by the rotating member case 43 .

[0100] Alternatively, the rotating member 41 may be configured to move in an arc direction with the horizontal axis H as a reference together with the rotating member housing 43 .

[0101] The bending device 40 has a structure in which the material coil 9 passed through the nozzle 20 is inserted between roller members 45 to be shaped.

[0102] Figure 6 is a structural diagram showing a horizontal moving device of a coil bending device for a hairpin type stator coil forming system applied to an embodiment of the present disclosure.

[0103] Reference Figure 6 In an exemplary embodiment of the present disclosure, the horizontal moving device 50 is disposed behind the partition 11 with the partition 11 of the housing 10 as a reference.

[0104] The horizontal moving device 50 includes a first plate 53 slidably mounted on the partition plate 11 in the left-right direction.

[0105] The first plate 53 is slidably mounted on the partition plate 11 via upper and lower guide rails 57 .

[0106] The first plate 53 is formed with a rectangular second through hole 55 corresponding to the first through hole 13 of the separator 11 .

[0107] At this time, the nozzle 20 supported by the partition plate 11 is disposed through the second through hole 55 .

[0108] In addition, the first plate 53 is connected to the first actuator 51 in a state of being mounted on the partition plate 11 through the upper and lower rails 57 .

[0109] The first actuator 51 is connected to the first plate 53 through a fixing block 59 which is connected to the front end of the driving shaft 511 .

[0110] That is, the first plate 53 is installed to be able to slide in the horizontal (left-right) direction by the upper and lower guide rails 57 in a state of being connected to the first actuator 51 through the fixing block 59 .

[0111] For example, the drive shaft 511 of the first actuator may be a linear guide.

[0112] The horizontal moving device 50 has a structure in which a first plate 53 connected to a driving shaft 511 of a first actuator 51 changes a position of the bending device 40 in the left-right direction while moving in the left-right direction by operation of the first actuator 51 .

[0113] Figure 7 is a structural diagram showing a vertical moving device of a coil bending device for a hairpin-type stator coil forming system applied to an embodiment of the present disclosure.

[0114] Reference Figure 7 In an exemplary embodiment of the present disclosure, the vertical moving device 60 is disposed behind the first plate 53 with the first plate 53 of the horizontal moving device 50 as a reference.

[0115] The vertical moving device 60 includes a second plate 63 slidably mounted on the first plate 53 in the up-down direction.

[0116] The second plate 63 is slidably mounted on the first plate 53 in the vertical direction via left and right guide rails 67 .

[0117] A circular third through hole 65 is formed in a central portion of the second plate 63 .

[0118] At this time, the nozzle 20 supported by the partition plate 11 is disposed through the third through hole 65 .

[0119] In addition, the second plate 63 is connected to the second actuator 61 in a state of being mounted on the first plate 53 through the left and right guide rails 67 .

[0120] The second actuator 61 is disposed above the housing 10 , and is connected to the second plate 63 through a driving shaft 611 of the second actuator 61 .

[0121] At this time, the second plate 63 is connected to the driving shaft 611 of the second actuator through the mounting bracket 69 .

[0122] That is, the second plate 63 is supported on the left and right guide rails 67 in a state of being connected to the second actuator 61 through the mounting bracket 69 and is mounted so as to be slidable in the up-down direction.

[0123] For example, the driving shaft 611 of the second actuator 61 may be a linear guide.

[0124] In addition, the vertical moving device 60 includes auxiliary cylinders 68 provided on both sides of the second actuator 61 .

[0125] The assist cylinder 68 applies a driving force to the second plate 63 in the up-down direction together with the second actuator 61 .

[0126] That is, the assist cylinder 68 serves to assist the second actuator 61 to easily slide the second plate 63 in the vertical direction.

[0127] In the vertical moving device 60 , as the second plate 63 connected to the driving shaft 611 of the second actuator 61 moves up and down by the operation of the second actuator 61 and the auxiliary cylinder 68 , the up-down direction position of the bending device 40 is changed.

[0128] Figure 8 is a structural diagram showing a first rotating device of a coil bending device for a hairpin-type stator coil forming system according to an embodiment of the present disclosure.

[0129] Reference Figure 8 In an exemplary embodiment of the present disclosure, the first rotating device 70 includes: a first driving gear 75, which is driven by a third actuator 71; a first driven gear 77, which is meshed with the first driving gear 75; and a third plate 73, which is connected to the first driven gear 77 and mounted on the third through hole 65 of the second plate 63.

[0130] The third plate 73 has a disc shape, and is rotatably mounted relative to the second plate 63 .

[0131] The first driving gear 75 and the first driven gear 77 may be planetary gears having different gear diameters.

[0132] At this time, the third actuator 71 is installed through the mounting bracket 69 , and the first driving gear 75 is disposed on the driving shaft 711 of the third actuator 71 .

[0133] The first rotating device 70 is connected to the bending device 40 through a rotating device housing 79 .

[0134] One end of the rotating device housing 79 is coupled to the rotating member housing 43 of the bending device 40 , and the other end of the rotating device housing 79 is coupled to the third plate 73 .

[0135] That is, the rotating device case 79 is used to connect the bending device 40 and the third plate 73 to transmit the driving force of the third actuator 71 to the bending device 40 .

[0136] In addition, in the first rotating device 70, the third actuator 71 is mounted through the mounting bracket 69, and the third plate 73 and the first driven gear 77 are mounted on the second plate 63. Therefore, when the vertical moving device 60 moves, the vertical moving device 60 moves together with the first rotating device 70.

[0137] In the first rotating device 70, the first driving gear 75 and the first driven gear 77 are rotated by the operation of the third actuator 71. Then, the third plate 73 coupled to the first driven gear 77 is rotated. At the same time, the rotating device housing 79 and the bending device 40 coupled to the third plate 73 move in the arc direction with the horizontal axis as a reference.

[0138] Fig. 9 is a structural diagram showing a second rotating device applied to a coil bending device for a hairpin type stator coil forming system according to an embodiment of the present disclosure, Fig.10 is a structural diagram illustrating connection between a second rotating device and a bending device of a coil bending device for a hairpin-type stator coil forming system according to an embodiment of the present disclosure.

[0139] Reference Fig. 9In an exemplary embodiment of the present disclosure, the second rotating device 80 includes: a second driving gear 83, which is driven by a fourth actuator 81; a second driven gear 85, which is meshed with the second driving gear 83; and a secondary driven gear 89, which is operated by the second driven gear 85 and connected to the rotating member 41 of the bending device 40.

[0140] At this time, the second driven gear 85 is formed integrally with a connecting driven gear 87 which is formed behind the second driven gear 85 and has a smaller diameter.

[0141] The connecting driven gear 87 is formed integrally with the second driven gear 85 , and directly meshes with the counter driven gear 89 while passing through the inside of the first driven gear 77 .

[0142] The second driving gear 83 , the second driven gear 85 , the connecting driven gear 87 , and the auxiliary driven gear 89 may be planetary gears having different gear diameters.

[0143] In addition, like the third actuator 71 , the fourth actuator 81 is mounted through the mounting bracket 69 , and the second driving gear 83 is provided on the driving shaft 811 of the fourth actuator 81 .

[0144] The second rotating device 80 is connected to the bending device 40 through a horizontal driving unit 90 .

[0145] The horizontal driving unit 90 is disposed inside the rotating device housing 79 , one end of the horizontal driving unit 90 passes through the rotating member housing 43 and is coupled to the rotating member 41 of the bending device 40 , and the other end of the horizontal driving unit 90 is coupled to the sub-driven gear 89 .

[0146] That is, the horizontal driving unit 90 is used to transmit the driving force of the fourth actuator 81 to the bending device 40 .

[0147] In addition, the second rotating device 80 has a structure in which the fourth actuator 81 is mounted through the mounting bracket 69 and the second driven gear 85 is mounted on the second plate 63 so that when the vertical moving device 60 moves, the vertical moving device 60 and the second rotating device 80 move together.

[0148] In the second rotating device 80, the second driving gear 83, the second driven gear 85 and the connecting driven gear 87 are rotated by the operation of the fourth actuator 81, and the sub driven gear 89 engaged with the connecting driven gear 87 is rotated. At the same time, the bending device 40 coupled to the horizontal driving unit 90 rotates with the vertical axis V as a reference.

[0149] At this time, refer to Fig.10 The rotation force of the second rotating device 80 is transmitted to the bending device 40 through a bevel gear (not shown) between one end of the horizontal driving unit 90 and the rotating member 41 .

[0150] Therefore, compared with the existing stamping forming method, the coil bending device for the hairpin type stator coil forming system according to the exemplary embodiment of the present disclosure can improve process flexibility through the separate position control of the nozzle and the bending device for forming the material coil.

[0151] In addition, the coil bending device for a hairpin type stator coil forming system according to an exemplary embodiment of the present disclosure simplifies the structure for controlling the position of the nozzle and the bending device, and can be applied regardless of the shape and type of the stator coil, thereby reducing investment and process costs.

[0152] In addition, the coil bending device for a hairpin type stator coil forming system according to an exemplary embodiment of the present disclosure can minimize the number of gear overlaps to minimize the tooth gap of the gears, and by reducing the tooth gap, the material coil can be accurately formed to improve productivity.

[0153] While the present disclosure has been described in conjunction with what are presently considered to be practical exemplary embodiments, it will be understood that the present disclosure is not limited to the disclosed embodiments. On the contrary, the present disclosure is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. A coil bending device for a hairpin type stator coil forming system, which bends a square material coil into a set shape, the coil bending device comprising: case; a tubular nozzle disposed through a horizontally central portion of the housing, the material coil being supplied through an interior of the tubular nozzle; a nozzle moving device connected to one end of the tubular nozzle and moving the tubular nozzle in one direction; a bending device including a pair of roller members on an upper surface of a rotating member provided corresponding to the other end of the tubular nozzle, and sandwiching the material coil discharged from the tubular nozzle between the pair of roller members to bend the material coil into the set shape; a horizontal moving device for moving the bending device in a horizontal direction via a first plate slidably mounted on the housing; a vertical moving device for moving the bending device in a vertical direction via a second plate slidably mounted on the first plate; a first rotating device for rotating the bending device about a horizontal axis via a third plate rotatably mounted on the second plate; as well as a second rotating device for rotating the bending device with respect to a vertical axis by operation of a planetary gear mounted on the second plate, wherein the nozzle moving device comprises a moving device actuator for actuating the nozzle moving device, The horizontal moving device comprises: a first actuator, which is mounted on the housing and connected to the first plate through a fixing block mounted on the front end of the driving shaft, and moves the first plate in a horizontal direction, The vertical moving device comprises: A second plate, disposed at the rear side of the first plate and slidably mounted on the first plate via left and right guide rails; and a second actuator, disposed on an upper side of the housing and connected to the second plate through a mounting bracket to move the second plate in a vertical direction, The vertical moving device further comprises: an auxiliary cylinder connected between the housing and the mounting bracket and applying a driving force to the second plate together with the second actuator, The drive shaft of the moving device actuator is formed as a linear guide.

2. The coil bending device for a hairpin type stator coil forming system according to claim 1, wherein: The tubular nozzle has a cylindrical shape with a hollow interior.

3. The coil bending device for a hairpin type stator coil forming system according to claim 1, wherein: The nozzle moving device further comprises: A mobile device bracket, disposed on the front side of the housing; The mobile device actuator is mounted on the mobile device bracket; and A connecting bracket is installed between the driving shaft of the moving device actuator and the front end of the tubular nozzle, and enables the tubular nozzle to slide forward and backward along the connecting guide rail on the moving device bracket.

4. The coil bending device for a hairpin type stator coil forming system according to claim 1, wherein: The bending device comprises: Rotating components rotate around a vertical axis; a rotating member housing surrounding a portion of the rotating member; and The pair of roller members, while being mounted on the upper surface of the rotating member protruding a portion from the rotating member housing, are arranged corresponding to the outlet of the tubular nozzle that discharges the material coil, and the material coil is clamped between the pair of roller members to bend the material coil into the set shape.

5. The coil bending device for a hairpin type stator coil forming system according to claim 1, wherein: The horizontal moving device further comprises: The first plate is arranged at the rear of the shell and is slidably mounted on the shell through upper and lower guide rails.

6. The coil bending device for a hairpin type stator coil forming system according to claim 1, wherein: The first rotating device comprises: a disc-shaped third plate rotatably mounted to a central portion of the second plate; a rotating device housing, one end of which is coupled to a rotating member housing surrounding the rotating member, and the other end of which is coupled to the third plate to rotate the bending device with the horizontal axis as a reference through the rotation of the third plate; a third actuator, which is mounted via the mounting bracket of the vertical moving device and has a first driving gear formed at the front end; and A first driven gear is meshed with the first driving gear and is coupled to a rear side of the third plate to rotate together with the third plate through the first driving gear as the third actuator is operated.

7. The coil bending device for a hairpin type stator coil forming system according to claim 6, wherein: As the third actuator operates, the first driven gear meshing with the first driving gear, the third plate coupled to the first driven gear, the rotating device housing coupled to the third plate, and the rotating member housing rotate, so that the bending device moves with reference to the horizontal axis.

8. The coil bending device for a hairpin type stator coil forming system according to claim 6, wherein: The first driving gear and the first driven gear are planetary gears having different gear diameters.

9. The coil bending device for a hairpin type stator coil forming system according to claim 6, wherein: The second rotating device comprises: A horizontal driving unit is arranged inside the housing of the rotating device, one end of the horizontal driving unit passes through the housing of the rotating member and is connected to the rotating member, and a secondary driven gear is arranged at the other end of the horizontal driving unit; a fourth actuator, mounted by the mounting bracket and having a second driving gear formed at a front end; a second driven gear meshing with the second driving gear and disposed in front of the first driven gear; and The connecting driven gear is formed behind the second driven gear and has a smaller diameter than the second driven gear, is formed integrally with the second driven gear, and meshes with the auxiliary driven gear while passing through the inside of the first driven gear.

10. The coil bending device for a hairpin type stator coil forming system according to claim 9, wherein: The second rotating device is configured to rotate the bending device about the vertical axis as the reference, as the fourth actuator operates, while the horizontal driving unit rotates through the second driven gear meshing with the second driving gear, the connecting driven gear formed integrally with the second driven gear, and the auxiliary driven gear meshing with the connecting driven gear.

11. The coil bending device for a hairpin type stator coil forming system according to claim 9, wherein: The second driving gear, the second driven gear, the counter driven gear, and the connecting driven gear are planetary gears having different gear diameters.

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