A flat wire hairpin slot guide device

Abstract

This invention provides a flat wire hairpin insertion guide device, including a bracket and a guide assembly capable of displacement along the horizontal and vertical directions of the bracket; and a lifting assembly disposed at the guide assembly mounting portion. The lifting assembly includes a front support rod disposed at the mounting portion and a rear support rod disposed behind the front support rod and capable of displacement along the vertical direction of the bracket to lift the rear leg of the hairpin to the front support rod for insertion of a subsequent hairpin. The lifting assembly of this invention can lift the rear leg of the previous hairpin when the hairpin is placed on the material cylinder mold, so that the front leg of the subsequent hairpin can be inserted below the rear leg of the previous hairpin, thereby achieving orderly wire winding by the flat wire motor. Simultaneously, the lifting assembly of this invention can also be displacement along the horizontal and vertical directions of the bracket to adjust to a position suitable for wire winding operations.

Description

Technical Field

[0001] This invention relates to the field of flat wire motor manufacturing technology, specifically to a flat wire hairpin slot guide device. Background Technology

[0002] Flat wire motors, due to their advantages such as high power density, low cost, and good temperature performance, are becoming a hot trend in the new energy drive motor industry. Existing flat wire motors generally employ a 4-layer or 8-layer flat wire structure, resulting in layered windings within the stator slots. Most multi-layer flat wire motors install their windings in the stator slots by placing them layer by layer. For single-layer flat wire windings, each subsequent hairpin must be positioned below the rear leg of the previous hairpin. Therefore, flat wire motors require high standards for hairpin manufacturing processes, manufacturing technology, and equipment automation. Traditional round wire motor production equipment is insufficient to meet these requirements. If the processing or installation precision of the flat wire motor hairpins is low, it will directly affect the motor's performance.

[0003] Regarding flat wire insertion, existing technologies include manual insertion of each wire individually. However, this method suffers from long processing cycles, high labor costs, and unstable product quality. While existing technologies also include automated insertion methods, such as patent application number 201911017644.0 and authorization announcement number CN110768489B, which discloses a device and method for inserting flat wire hairpins into a stator, the device includes a frame and a hairpin placement mold. The mold includes a barrel, several baffles that can extend and retract radially along the barrel wall, an elastic element for forcing the baffles to retract into the barrel cavity, a mandrel pull rod for manipulating the baffles to extend outward from the barrel, and a hairpin pusher sleeve fitted on the barrel. The baffles form hairpin placement grooves on the outer periphery of the barrel for placing all the flat wire hairpins required for the stator core. The pusher sleeve is used to push all the flat wire hairpins placed on the outer periphery of the barrel forward so that all the flat wire hairpins are pressed into the hairpin slots of the stator core. By placing the pre-formed hairpins layer by layer into a mold, they are first inserted into the stator core, thus avoiding the scraping between adjacent flat wires caused by the existing method of inserting them one by one. However, during the hairpin placement process, as mentioned earlier, the front leg of the next hairpin must be placed below the rear leg of the previous hairpin. Existing hairpin placement equipment lacks a support device for this process, resulting in low efficiency throughout the entire placement process. Summary of the Invention

[0004] To solve the above-mentioned technical problems, the present invention provides a flat wire hairpin guide device that lifts the rear leg of the previous hairpin when the hairpin is placed on the material cylinder mold, so as to allow the front leg of the subsequent hairpin to be inserted into the flat wire hairpin slot below the rear leg of the previous hairpin. The specific technical solution is as follows:

[0005] A flat wire hairpin slot guide device includes a bracket and further includes:

[0006] Guide assembly, the guide assembly being displaceable along the horizontal and vertical directions of the support; and

[0007] The lifting assembly is disposed in the guide assembly mounting part. The lifting assembly includes a front support rod disposed in the mounting part and a rear support rod disposed behind the front support rod and capable of displacement along the vertical direction of the bracket to lift the rear leg of the hairpin to the front support rod so as to facilitate the insertion of the next hairpin.

[0008] Preferably, the guiding assembly includes a horizontal servo screw mechanism and a vertical servo screw mechanism disposed in the mounting part of the horizontal servo screw mechanism.

[0009] Preferably, the horizontal servo screw mechanism includes a horizontal servo motor mounted on a bracket, a horizontal screw mounted at the output end of the horizontal servo motor, a horizontal screw nut screwed into the horizontal screw, and a horizontal mounting base mounted on the outer wall of the horizontal screw nut.

[0010] Preferably, the vertical servo screw mechanism includes a vertical servo motor mounted on a horizontal mounting base, a vertical screw mounted on the output end of the vertical servo motor, a vertical screw nut screwed into the vertical screw, and a vertical mounting base mounted on the outer wall of the vertical screw nut.

[0011] Preferably, the horizontal servo screw mechanism and the vertical servo screw mechanism are respectively equipped with sensors for limiting the displacement limits of the horizontal mounting base and the vertical mounting base.

[0012] Preferably, the front support member includes a front support rod vertically mounted on a vertical mounting base and at least two front support plates arranged parallel to each other on the side wall of the front support rod.

[0013] Preferably, the front support plate is vertically fixed to the top of the front support rod.

[0014] Preferably, the rear support rod includes a vertical cylinder fixed on a vertical mounting base, a rear support rod disposed at the output end of the vertical cylinder, and at least two parallel and spaced rear support plates disposed on the side wall of the rear support rod, wherein the rear support plates can be moved upward under the action of the vertical cylinder to be on the same horizontal plane as the front support plates.

[0015] Preferably, it also includes an auxiliary support member disposed on the rear side of the rear support member. The auxiliary support member includes a horizontal cylinder fixed on the vertical mounting base, an auxiliary support rod disposed on the output end of the horizontal cylinder, and an auxiliary support plate disposed on the side wall of the auxiliary support rod and located between the rear support plates.

[0016] Preferably, the auxiliary support plate extends in an arc shape towards the forward support rod.

[0017] As can be seen from the above technical solutions, the present invention has the following beneficial effects:

[0018] 1. In this invention, the rear support rod can be vertically displaced relative to the front support rod. In the initial state of each hairpin cycloidal line, the rear support rod is located below the rear side of the front support rod to reserve space for the robot arm to place the hairpins. The previous hairpin is grasped by the robot arm and its front leg is placed in the hairpin placement slot of the material cylinder mold, while the rear leg is placed on the rear support plate below the rear side. The rear support plate is driven by the vertical cylinder to raise the rear leg of the hairpin to the same horizontal height as the front support plate. As the material cylinder mold rotates, the rear leg of the hairpin moves to the front support plate, thereby lifting the rear leg of the hairpin. Then, the rear support plate is driven by the vertical cylinder to move down to the initial position so that the front leg of the next hairpin can be placed in the hairpin placement slot below the rear leg of the hairpin. Repeating the above steps can realize the placement of hairpins for a single layer of flat wire motor windings.

[0019] 2. In this invention, since the flat wire winding in the existing flat wire motor is arranged in multiple layers, the lifting component needs to be placed in a suitable position during the actual cycloidal process. Therefore, by setting up a horizontal servo screw mechanism and a vertical servo screw mechanism, the horizontal displacement of the horizontal servo screw mechanism and the vertical displacement of the vertical servo screw mechanism can be used to move the lifting component in this invention to a suitable position to lift the back leg of the hairpin, so as to facilitate the smooth progress of the cycloidal operation. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of the present invention;

[0021] Figure 2 for Figure 1 Side view;

[0022] Figure 3 for Figure 1 A magnified view of part A in the middle.

[0023] In the diagram: 10, bracket; 20, guide assembly; 210, horizontal servo screw mechanism; 211, horizontal servo motor; 212, horizontal screw; 220, vertical servo screw mechanism; 221, vertical servo motor; 222, vertical mounting base; 30, lifting assembly; 310, front support rod; 311, front support rod; 312, front support plate; 320, rear support rod; 321, vertical cylinder; 322, rear support rod; 323, rear support plate; 330, auxiliary support; 331, horizontal cylinder; 332, auxiliary support rod; 333, auxiliary support plate. Detailed Implementation

[0024] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. Before describing the technical solutions of each embodiment of the present invention in detail, the terms and terms involved will be explained. In this specification, components with the same name or the same reference numerals represent similar or the same structures and are limited to illustrative purposes.

[0025] Example:

[0026] Reference Figure 1 , Figure 2 A flat wire hairpin insertion guide device includes a bracket 10, a guide assembly 20, and a lifting assembly 30. The guide assembly is movable horizontally and vertically along the bracket. The lifting assembly is disposed at the guide assembly mounting part. The lifting assembly includes a front support rod 310 disposed at the mounting part and a rear support rod 320 disposed behind the front support rod and movable vertically along the bracket to lift the rear leg of the hairpin to the front support rod for insertion of the next hairpin. In use, the guide device is positioned above the hairpin placement mold. Initially, the rear support rod is located below the rear of the front support rod. The machine is designed with a pre-reserved space. The hair clip is picked up by a robotic arm and placed in the hair clip placement slot on the material cylinder through the pre-reserved space. The rear leg of the hair clip is placed on the rear support rod. Then, the rear support rod is moved upward along the vertical direction of the support to raise the rear leg of the hair clip to the same level as the front support rod. As the material cylinder rotates, it drives the hair clip to rotate synchronously, thereby moving the rear leg of the hair clip onto the front support rod, thus raising the rear leg of the hair clip. Then, the rear support rod moves downward so that the front leg of the next hair clip can be inserted into the hair clip placement slot on the material cylinder below the rear leg of the previous hair clip.

[0027] As a preferred technical solution of the present invention, the guide assembly 20 includes a horizontal servo screw mechanism 210 and a vertical servo screw mechanism 220 disposed on the mounting part of the horizontal servo screw mechanism. The horizontal servo screw mechanism includes a horizontal servo motor 211 disposed on the bracket, a horizontal screw 212 rotatably disposed on the output end of the horizontal servo motor, a horizontal screw nut screwed with the horizontal screw, and a horizontal mounting seat disposed on the outer wall of the horizontal screw nut. Thus, when the horizontal servo motor is working, it drives the horizontal screw nut to move along the axial direction of the horizontal screw, thereby realizing the horizontal displacement of the horizontal mounting seat and its components along the bracket.

[0028] Furthermore, the vertical servo screw mechanism 220 includes a vertical servo motor 221 mounted on a horizontal mounting base, a vertical screw rotatably mounted at the output end of the vertical servo motor, a vertical screw nut screwed into the vertical screw, and a vertical mounting base 222 mounted on the outer wall of the vertical screw nut. Thus, when the vertical servo motor is working, it drives the vertical screw nut to move axially along the vertical screw, thereby realizing the vertical displacement of the vertical mounting base and its components along the support.

[0029] Since the existing flat wire motor has multiple windings, the position of the lifting component needs to be adjusted accordingly when placing hairpins of different layers. Therefore, the horizontal displacement function of the horizontal servo screw mechanism 210 and the vertical displacement function of the vertical servo screw mechanism 220 can be used to realize the horizontal and vertical displacement of the lifting component, thereby adjusting the lifting component to the optimal working position.

[0030] Furthermore, sensors for limiting the displacement limits of the horizontal mounting base and the vertical mounting base 222 are respectively provided on the horizontal servo screw mechanism 210 and the vertical servo screw mechanism 220. Specifically, the sensors can be respectively set on the support frame for fixing the servo motor and correspond to the displacement limit positions of the horizontal mounting base and the vertical mounting base. In this way, when the horizontal mounting base and the vertical mounting base move to the limit position, the corresponding motor is triggered to stop, preventing the lifting component from moving too much.

[0031] Reference Figure 3 As a preferred technical solution of the present invention, the front support rod 310 includes a front support rod 311 vertically mounted on a vertical mounting base and a front support plate 312 fixed to the top of the front support rod. Specifically, the front support plate is a long strip plate that can be fixed to the front support rod by screws or other fasteners. Correspondingly, in order to facilitate the fixing of the front support plate, the top of the front support rod can be made into a plane, so as to facilitate the fixing of the front support plate on it.

[0032] Furthermore, the number of front support plates 312 is at least two. When there are two front support plates, the two front support plates are arranged in parallel intervals, and the space formed by the gap between the two front support plates facilitates the robot arm to place the grasped hair clips into the hair clip placement slot of the material cylinder. In addition, the front support plates in this invention can be arranged perpendicular to the front support rod or at a certain angle to the front support rod. Preferably, they are designed to be arranged perpendicular to the front support rod, so as to facilitate the robot arm to place the hair clips into the hair clip placement slot of the material cylinder.

[0033] As a preferred technical solution of the present invention, the rear support rod 320 includes a vertical cylinder 321 fixed on a vertical mounting base, a rear support rod 322 disposed at the output end of the vertical cylinder, and a rear support plate 323 disposed on the side wall of the rear support rod. Specifically, the rear support plate is also a long strip plate, which is also fixed to the front support rod by fasteners such as screws. Correspondingly, in order to facilitate the fixing of the rear support plate, the top of the rear support rod can be made into a plane, thereby facilitating the fixing of the rear support plate.

[0034] Furthermore, there are at least two rear support plates 323, the same number as the front support plates 312. When there are two rear support plates, the two rear support plates are arranged in parallel at intervals on the top of the rear support rod.

[0035] The hairpin placement process is as follows: Initially, the rear support rod is located below and behind the front support rod, leaving space for the robot arm to move between the rear and front support rods. The hairpin is grasped by the robot arm and, through the aforementioned space and the gap between the front support plate, the front leg of the hairpin is placed into the hairpin placement slot of the material cylinder, while the rear leg rests on the rear support plate. Then, driven by the vertical cylinder, the rear support plate moves vertically to the same horizontal height as the front support plate. Subsequently, the material cylinder drives the hairpin to rotate, and the rear leg of the hairpin moves from the rear support plate to the front support plate, thereby lifting the rear leg of the hairpin. Then, driven by the vertical cylinder, the rear support plate moves vertically downward to the initial position to leave the aforementioned space, thus facilitating the insertion of the front leg of the next hairpin. The above steps are repeated until the hairpins for the single-layer flat wire motor winding are placed.

[0036] As a preferred technical solution of the present invention, it further includes an auxiliary support 330 disposed on the rear side of the rear support member. The auxiliary support includes a horizontal cylinder 331 fixed on the vertical mounting base, an auxiliary support rod 332 disposed on the output end of the horizontal cylinder, and an auxiliary support plate 333 disposed on the side wall of the auxiliary support rod. The auxiliary support plate is located between the rear support plates 323 and extends in an arc shape towards the front support rod. By setting the auxiliary support, when the rear leg of the hairpin is placed on the rear support plate, it can be further supported by the aforementioned auxiliary support plate. When it is necessary to lift the rear leg onto the front support plate, the displacement of the horizontal cylinder can be used to pull the auxiliary support plate away from the rear support plate, thus avoiding interference with the movement of the rear support plate.

[0037] The above-described embodiments are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A flat wire hair clip slot guide device, comprising a bracket (10), characterized in that, Also includes: Guide assembly (20), the guide assembly being capable of displacement along the horizontal and vertical directions of the support; as well as The lifting component (30) is provided in the guide component mounting part. The lifting component includes a front support rod (310) provided in the mounting part and a rear support rod (320) provided behind the front support rod and capable of displacement in the vertical direction of the bracket to lift the rear leg of the hairpin to the front support rod so as to facilitate the insertion of the next hairpin. The front support member (310) includes a front support rod (311) vertically mounted on a vertical mounting base and at least two front support plates (312) arranged parallel to each other on the side wall of the front support rod. The rear support rod (320) includes a vertical cylinder (321) fixed on a vertical mounting base, a rear support rod (322) disposed at the output end of the vertical cylinder, and at least two parallel and spaced rear support plates (323) disposed on the side wall of the rear support rod. The rear support plates can be moved upward under the drive of the vertical cylinder to be on the same horizontal plane as the front support plate.

2. The flat wire hairpin slot guide device according to claim 1, characterized in that, The guide assembly (20) includes a horizontal servo screw mechanism (210) and a vertical servo screw mechanism (220) disposed in the mounting part of the horizontal servo screw mechanism.

3. The flat wire hairpin slot guide device according to claim 2, characterized in that, The horizontal servo screw mechanism includes a horizontal servo motor (211) mounted on a bracket, a horizontal screw (212) mounted at the output end of the horizontal servo motor, a horizontal screw nut screwed into the horizontal screw, and a horizontal mounting base mounted on the outer wall of the horizontal screw nut.

4. The flat wire hairpin slot guide device according to claim 3, characterized in that, The vertical servo screw mechanism (220) includes a vertical servo motor (221) mounted on a horizontal mounting base, a vertical screw mounted on the output end of the vertical servo motor, a vertical screw nut screwed into the vertical screw, and a vertical mounting base (222) mounted on the outer wall of the vertical screw nut.

5. The flat wire hairpin slot guide device according to claim 4, characterized in that, The horizontal servo screw mechanism (210) and the vertical servo screw mechanism (220) are respectively equipped with sensors (40) for limiting the displacement limits of the horizontal mounting base and the vertical mounting base (222).

6. The flat wire hairpin slot guide device according to claim 1, characterized in that, The front support plate (312) is vertically fixed to the top of the front support rod.

7. The flat wire hairpin slot guide device according to claim 6, characterized in that, It also includes an auxiliary support (330) disposed on the rear side of the rear support member. The auxiliary support includes a horizontal cylinder (331) fixed on the vertical mounting base, an auxiliary support rod (332) disposed on the output end of the horizontal cylinder, and an auxiliary support plate (333) disposed on the side wall of the auxiliary support rod and located between the rear support plate (323).

8. The flat wire hairpin slot guide device according to claim 7, characterized in that, The auxiliary support plate (333) extends in an arc shape towards the forward support rod.

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