A coil compression unit, tooling and method

Abstract

This invention provides a coil compression unit, tooling, and method. The coil compression unit includes a winding post, a housing, a base, a punch, and a wire release mechanism. The winding post is disposed on the base, and the coil is detachably arranged on the winding post. The housing surrounds the coil, and the punch can slide between the winding post and the housing to compress the coil. The wire release mechanism is used to separate the compressed coil from the winding post. This prevents the lead wire from bending and damaging its insulation layer, thereby extending its service life. Furthermore, the wire release mechanism separates the compressed coil from the winding post, preventing excessive pressure between the coil and the winding post that could lead to an inability to separate them.

Description

Technical Field

[0001] This invention relates to the field of motor coils, and more particularly to a coil compression unit, tooling, and method. Background Technology

[0002] The coil winding is a major component of the motor stator. It consists of coils connected in a specific way on the stator core to form the stator circuit. The relative motion between the coil winding and the rotor magnetic flux generates an induced electromotive force, realizing the conversion of mechanical energy into electrical energy. The coil winding typically consists of coils of the same shape and size embedded in the teeth of the stator core, connected by bridging wires or similar means. The coils are made of enameled wire, but currently, coil winding is mainly done mechanically or manually, which is not only inefficient but also leaves uneven gaps between conductors, resulting in low utilization of the slot space.

[0003] During motor operation, the coil generates heat, and the gaps between conductors hinder heat conduction, causing the coil temperature to rise. Overheating can damage the insulation layer on the coil surface, leading to short circuits between the enameled wires and potentially burning out the motor. Therefore, coil compression is necessary to improve the utilization of slot space. Coil compression is primarily accomplished using coil compression equipment, but current coil compression equipment has the following drawbacks:

[0004] First, in order to accommodate the coil's placement on the coil compression equipment, the coil's leads need to be bent multiple times, which damages the insulation layer and consequently affects its service life.

[0005] Secondly, the coil is difficult to separate after being compressed on the coil compression equipment, making it difficult to take the coil wire out, and improper operation can affect the compression of the coil after taking the wire out.

[0006] Third, the coils are compressed one by one using equipment, and then the coils need to be welded together to form a whole, which greatly reduces the forming efficiency. Summary of the Invention

[0007] To address the aforementioned issues, this invention provides a coil compression unit, tooling, and method that improves the utilization rate of the slot space to enhance heat dissipation, prevents the coil lead wire from being damaged by repeated bending, facilitates coil wire extraction, and can compress multiple coils simultaneously, eliminating the welding step to improve the efficiency of wire embedding.

[0008] According to one object of the present invention, a coil compression unit is provided, comprising a winding post, a housing, a base, a punch, and a decoupling mechanism, wherein the winding post is disposed on the base, a coil is detachably arranged on the winding post, the housing surrounds the coil, and the punch is slidable between the winding post and the housing to compress the coil, and the decoupling mechanism is used to separate the compressed coil from the winding post.

[0009] In a preferred embodiment, the decoupling mechanism includes at least one inclined surface disposed on the outer surface of the winding post, so that the coil can slide off along the inclined surface.

[0010] In a preferred embodiment, the unwinding mechanism includes at least one set screw hole, and the bottom of the winding post extends outward to form an extension body, with the set screw hole disposed on the extension body.

[0011] In a preferred embodiment, the decoupling mechanism includes at least one inclined surface disposed inside the winding post to divide the winding post into two mutually sliding winding blocks, so that the coil can slide off as the winding blocks slide against each other.

[0012] In a preferred embodiment, the housing is provided with a lead hole corresponding to the end of the coil, so that the lead wire connected to the end of the coil is led out from the lead hole in a non-bending manner.

[0013] In a preferred embodiment, the base has an abutting surface that abuts against the lower end face of the coil, and the abutting surface is provided with a wire outlet groove for accommodating the lead wire, and the wire outlet groove extends in a straight line between the end of the coil and the wire outlet hole.

[0014] In a preferred embodiment, the contact surface or the lower surface of the punch is partially inclined to form a slope.

[0015] According to another objective of the present invention, the present invention also provides a coil compression fixture, comprising a plurality of coil compression units as described above, wherein the plurality of coil compression units provide compression for individual coils wound integrally.

[0016] In a preferred embodiment, a plurality of the coil compression units are stacked from bottom to top, and the punch of the current coil compression unit is integrally formed with the base of the previous coil compression unit.

[0017] In a preferred embodiment, the base includes a base plate, the winding post is fixed to the base plate, and the outer shell abuts between the base plates of two adjacent coil compression units.

[0018] In a preferred embodiment, the base further includes a pressure block disposed on the base plate and located between the winding post and the outer casing, so as to compress the coil between the pressure block and the punch.

[0019] According to another objective of the present invention, the present invention also provides a coil compression method, comprising the following steps:

[0020] S100, the coil is arranged on the winding post;

[0021] S200, provides a housing with a wire outlet hole, the housing is fixed to the periphery of the coil, and the lead wire connected to the end of the coil is led out from the wire outlet hole in a non-bending manner;

[0022] S300, the punch is slid between the winding post and the housing to compress the coil;

[0023] S400, remove the punch and the housing, and the compressed coil and the winding post are separated by the wire-removing mechanism.

[0024] In a preferred embodiment, the decoupling mechanism includes at least one inclined surface disposed on the outer surface of the winding post, and then in step S400, the coil slides off along the inclined surface.

[0025] In a preferred embodiment, the wire-removing mechanism includes at least one set screw hole, the bottom of the winding post extends outward to form an extension body, the set screw hole is disposed on the extension body, and then in step S400, the coil is slid away by passing a set screw tool through the set screw hole.

[0026] In a preferred embodiment, the decoupling mechanism includes at least one inclined surface disposed inside the winding post to divide the winding post into two mutually sliding winding blocks. Thus, in step S400, the coil slides away as the winding blocks slide against each other.

[0027] Compared with existing technologies, this technical solution has the following advantages:

[0028] The outer casing is provided with a lead-out hole corresponding to the end of the coil, so that the lead wire connected to the end of the coil can be led out from the lead-out hole in a non-bending manner, preventing the lead wire from bending and damaging its insulation layer, thereby extending its service life. Furthermore, the wire-removing mechanism separates the compressed coil from the winding post, preventing excessive pressure between the coil and the winding post from causing separation failure. By providing a lead-out hole connecting the compression space and the outside, a lead wire integrally wound and located between two adjacent coils is led out. Multiple integrally wound coils are compressed together, eliminating the subsequent welding step between coils compared to the existing method of compressing one coil at a time, thus effectively improving the winding forming efficiency. In addition, the coil compression unit compresses the coil, expelling air between the coils, improving the utilization rate of the slot space, and thus improving heat dissipation performance. The pressure block of the base has a lead-out groove to accommodate the lead wire, preventing excessive pressure from the punch compressing the coil and damaging the insulation layer of the lead wire. The contact surface is inclined to form a ramp, which increases the space on the upper surface of the pressure block to reduce pressure. This does not affect assembly and also reduces the probability of insulation damage.

[0029] The present invention will be further described below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the structure of the first embodiment of the coil compression fixture of the present invention;

[0031] Figure 2 This is a schematic diagram of the structure of the first embodiment of coil compression according to the present invention;

[0032] Figure 3 This is a schematic diagram of the assembly of the base and the winding post in the first embodiment of the coil compression of the present invention;

[0033] Figure 4 This is a schematic diagram of the assembly of the coil and the winding post in the first embodiment of the coil compression of the present invention;

[0034] Figure 5 This is a perspective view of the base in the first embodiment of the coil compression of the present invention;

[0035] Figure 6 This is a schematic diagram of the bottom of the base in the first embodiment of the coil compression of the present invention;

[0036] Figure 7 This is a schematic diagram of the coil stacking in the first embodiment of the coil compression of the present invention;

[0037] Figure 8 This is a schematic diagram of the integrally wound coil structure described in this invention;

[0038] Figure 9This is an exploded view of the second embodiment of coil compression according to the present invention;

[0039] Figure 10 This is a schematic diagram of the second embodiment of the coil compression described in this invention;

[0040] Figure 11 This is a schematic diagram of the assembly of the winding post and the coil in the second embodiment of the coil compression of the present invention;

[0041] Figure 12 This is a schematic diagram of the winding post structure in the second embodiment of the coil compression of the present invention;

[0042] Figure 13 This is a schematic diagram of the base structure in the second embodiment of the coil compression of the present invention;

[0043] Figure 14 This is an exploded view of the third embodiment of coil compression according to the present invention;

[0044] Figure 15 This is a schematic diagram of the third embodiment of the coil compression described in this invention;

[0045] Figure 16 This is a schematic diagram of the fourth embodiment of the coil compression described in this invention;

[0046] Figure 17 This is an exploded view of the winding post in the fourth embodiment of the coil compression of the present invention;

[0047] Figure 18 This is a schematic diagram of the sliding of the winding post in the fourth embodiment of the coil compression of the present invention;

[0048] Figure 19 This is a schematic diagram of the base structure in the fourth embodiment of the coil compression of the present invention. Detailed Implementation

[0049] The following description is intended to disclose the present invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art. The basic principles of the invention defined in the following description can be applied to other embodiments, modifications, improvements, equivalents, and other technical solutions that do not depart from the spirit and scope of the invention.

[0050] like Figures 1 to 19As shown, the coil compression unit 100a-100d includes winding posts 110a-110d, a housing 120, a base 130a-130d, a punch 140, and a wire release mechanism 150b-150d. The winding posts 110a-110d are disposed on the base 130a-130d, and the coil 210 is detachably arranged on the winding posts 110a-110d. The housing 120 surrounds the coil 210, and the punch 140 can slide between the winding posts 110a-110d and the housing 120 to compress the coil 210. The wire release mechanism 150b-150d is used to separate the compressed coil 210 from the winding posts 110a-110d.

[0051] The decoupling mechanisms 150b-150d are used to separate the compressed coil 210 from the winding posts 110a-110d, preventing excessive pressure between the coil 210 and the winding posts 110a-110d from causing the wire to fail to separate. The decoupling mechanisms 150b-150d are described in detail below through three embodiments:

[0052] First Embodiment

[0053] like Figures 9 to 13 As shown, the decoupling mechanism 150b includes at least one inclined surface 151b, which is disposed on the outer surface of the winding post 110b to allow the coil 210 to slide off along the inclined surface 151b. It is evident that the outer surface of the winding post 110b has an incline. As the coil 210 slides along the inclined surface 151b, the gap between the coil 210 and the inclined surface 151b increases, relieving the pressure between the winding post 110b and the coil 210, thus facilitating the sliding of the coil 210 relative to the winding post 110b.

[0054] Specifically, the winding post 110b includes an upper bottom surface 1101, a lower bottom surface 1102, and a side surface 1103 connecting the upper bottom surface 1101 and the lower bottom surface 1102. The area of ​​the upper bottom surface 1101 is smaller than the area of ​​the lower bottom surface 1102, so that the side surface 1102 is inclined between the upper bottom surface 1101 and the lower bottom surface 1102. That is, the inclined side surface 1102 becomes the inclined surface 151b. At this time, the cross-section of the winding post 110b gradually decreases from bottom to top. The coil 210 is wound around the winding post 110b along the side surface 1103 so that the compressed coil 210 can be taken out from the top of the winding post 110b.

[0055] like Figure 12As shown, both the upper bottom surface 1101 and the lower bottom surface 1102 are trapezoidal to accommodate the trapezoidal and annular coil 210. The base 130b, the coil 210, and the punch 140 have the same shape, all being trapezoidal annular structures. The base 130b is fitted onto the bottom of the winding post 110b so that when the punch 140 presses downwards, the coil 210 can be compressed between the base 130b and the punch 140.

[0056] The outer casing 120 is provided with a wire outlet hole 1002 corresponding to the end of the coil 210, so that the lead wire 220 connected to the end of the coil 210 can be led out from the wire outlet hole 1002 in a non-bending manner. The outer casing 120 is provided with a wire outlet hole 1002 corresponding to the end of the coil 210, so that the lead wire 220 connected to the end of the coil 210 can be led out from the wire outlet hole 1002 in a non-bending manner, preventing the lead wire 220 from being bent and damaging its insulation layer, thereby extending its service life.

[0057] like Figure 13 As shown, the base 130b has an abutting surface 1301 that abuts against the lower end face of the coil 210. The abutting surface 1301 is provided with a wire outlet groove 1302 for accommodating the lead wire 220, and the wire outlet groove 1302 extends in a straight line between the end of the coil 210 and the wire outlet hole 1002.

[0058] Since the lead wire 220 is housed in the lead slot 1302, the excessive pressure exerted by the punch 140 on the coil 210 is prevented from damaging the insulation layer of the lead wire 220.

[0059] The lead wire 220 extends from the bottom of the trapezoid of the coil 210, and the lead wire groove 1302 is located at the bottom of the trapezoid of the base 130b. The lead wire groove 1302 extends from the inner and outer edges of the bottom of the trapezoid of the base 130b, and is linearly opposite to the end of the coil 210 and the lead wire hole 1002, respectively. Thus, the lead wire groove 1302 and the lead wire hole 1002 are located in the same straight line direction, thereby allowing the lead wire 220 to pass through the lead wire hole 1002 without bending.

[0060] It should be noted that the coil 210 has two leads 220, which can correspond to the two leads 1302 respectively, or the two leads 220 can be led out through the same leads 1302. The lead positions can be adjusted according to engineering needs.

[0061] Continue to refer to Figure 13The contact surface 1301 is partially inclined to form a ramp 1303, which increases the space on the upper surface of the base 130b to reduce pressure, without affecting assembly, and also reduces the probability of insulation damage. Specifically, the ramp 1303 is located on the contact surface 1301 corresponding to the bottom of the trapezoid of the base 130b, which corresponds to the position where the coil 210 exits, that is, the exit groove 1302 is located on the ramp 1303. Of course, the ramp 1303 can also be located on the contact surface 1301 corresponding to the top of the trapezoid of the base 130b, or simultaneously on the contact surfaces 1301 corresponding to both the top and bottom of the trapezoid of the base 130b.

[0062] In addition, the ramp 1303 can also be located on the lower surface of the punch 140, corresponding to the abutment surface 1301 corresponding to the trapezoidal top and / or bottom of the punch 140. This can also reduce pressure, protect the coil insulation, and not affect assembly.

[0063] like Figure 9 and Figure 10 As shown, a compression space 1001 is formed between the outer shell 120 and the winding post 110b, wherein the outer shell 120 and the winding post 110b compress the inner and outer sides of the coil 210, while the punch 140 and the base 130b compress the upper and lower end faces of the coil 210, further improving the utilization rate of the slot space and thus improving the heat dissipation performance.

[0064] The outer casing 120 has a wire outlet hole 1002 opposite to the wire outlet groove 1302. The wire outlet hole 1002 is located at the bottom of the outer casing 120, so that when the outer casing 120 is arranged around the winding post 110b, the lead wire 220 is inserted into the wire outlet hole 1002 from the bottom of the outer casing 120.

[0065] like Figure 9 As shown, the base 130b is sleeved between the winding post 110b and the outer shell 120, that is, it is located inside the compression space 1001, or the base 130b is located outside the compression space 1001, that is, the outer shell 120 abuts against the base 130b.

[0066] The outer casing 120 can be a split structure, which not only facilitates assembly but also allows for tightening using fasteners, further enhancing the compression capability of the coil 210. Specifically, refer to... Figure 9The outer casing 120 includes at least two housings 121 and at least one fastener 122. The plurality of housings 121 surround the winding post 110b and are tightened by the fastener 122, wherein the fastener 122 may be a bolt, and the number may be multiple. One fastener tightens two housings 121, thereby improving the compression capacity of the coil 210.

[0067] In summary, the wire-removing mechanism 150b includes at least one inclined surface 151b, which is disposed on the outer surface of the winding post 110b. This allows the coil 210 to slide off along the inclined surface 151b, causing the cross-section of the winding post 110b to gradually decrease from bottom to top. This facilitates the placement of the coil 210 from top to bottom around the winding post 110b and also allows the compressed coil 210 to be removed from bottom to top, preventing improper wire removal from the compressed coil that could affect its compression. The outer shell 120 and the winding post 110b compress the inner and outer surfaces of the coil 210, while the punch 140 and the base 130b compress the upper and lower end faces of the coil 210, further improving the utilization rate of the slot space and thus enhancing heat dissipation performance. The base 130b has a lead-out groove 1302 to accommodate the lead wire 220, preventing the punch 140 from compressing the coil 210 with excessive pressure and damaging the insulation layer of the lead wire 220. The abutment surface 1301 of the base 130b is partially inclined to form a ramp 1303, which increases the space on the upper surface of the pressure block 132 to reduce pressure, without affecting assembly, and at the same time reduces the probability of insulation damage.

[0068] Second Embodiment

[0069] like Figure 14 and Figure 15 As shown, the unwinding mechanism 150c includes at least one set screw hole 113. The bottom of the winding post 110c extends outward to form an extension body 112, and the set screw hole 113 is disposed on the extension body 112. A set screw tool is used to push out the compressed coil 210 on the winding post 110c through the set screw hole 113, so that the coil 210 is removed relative to the winding post 110c.

[0070] Specifically, the winding post 110c includes a winding body 111 and an extension body 112. The extension body 112 extends outward and connects to the periphery of the bottom of the winding body 111. The set screw holes 113 are formed on the extension body 112. There can be multiple set screw holes 113; for example, each of the four corners of the extension body 112 may have a set screw hole 113. Figure 14 This is to give the coil 210 four points of action in four directions, so that the coil 210 can be removed.

[0071] refer to Figure 14 and Figure 15 The coil 210 and the base 130c are respectively sleeved on the winding body 111, and the base 130c is located between the coil 210 and the extension body 112.

[0072] The base 130c and the coil 210 have the same shape, both being trapezoidal annular structures. This allows the set screw tool to act on the base 130c to push the coil 210 out. This prevents the set screw tool from directly acting on the coil 210 and causing damage.

[0073] like Figure 14 As shown, the base 130c has an abutting surface 1301 that abuts the coil 210, and a wire outlet groove 1302 is provided on the abutting surface 1301.

[0074] The lead-out groove 1302 is located on the upper surface of the base 130c. The lead-out groove 1302 and the lead wire 220 of the coil 210 are opposite each other, so that the lead wire 220 is located inside the lead-out groove 1302, preventing the punch 140 from compressing the coil 210 with excessive pressure and damaging the insulation layer of the lead wire 220. The lead wire 220 extends from the bottom of the trapezoid of the coil 210, indicating that the lead-out groove 1302 is located at the bottom of the trapezoid of the base 130c.

[0075] Continue to refer to Figure 3 The contact surface 1301 is partially inclined to form a ramp 1303, which increases the space on the upper surface of the base 130c to reduce pressure, without affecting assembly, and also reduces the probability of insulation damage. Specifically, the ramp 1303 is located on the contact surface 1301 corresponding to the bottom of the trapezoid of the base 130c, which corresponds to the position where the coil 210 exits, that is, the exit groove 1302 is located on the ramp 1303. Of course, the ramp 1303 can also be located on the contact surface 1301 corresponding to the top of the trapezoid of the base 130c, or simultaneously on the contact surfaces 1301 corresponding to both the top and bottom of the trapezoid of the base 130c.

[0076] refer to Figure 9 , Figure 14 and Figure 15 The coil compression unit 100c further includes a housing 120, which is disposed around the winding post 110c to form a compression space 1001 between the housing 120 and the winding post 110c. The punch 140 is slidably connected within the compression space 1001. The contents of the housing 120 can be referred to in the first embodiment, and will not be described in detail here.

[0077] In summary, the wire removal mechanism 150c includes at least one set screw hole 113. The bottom of the winding post 110c extends outward to form an extension body 112. The set screw hole 113 is disposed on the extension body 112. A set screw tool is used to push out the compressed coil 210 on the winding post 110c through the set screw hole 113, so that the coil 210 is removed relative to the winding post 110c. The outer shell 120 and the winding post 110c compress the inner and outer sides of the coil 210, while the punch 140 and the base 130c compress the upper and lower end faces of the coil 210, further improving the utilization rate of the slot space and thus improving heat dissipation performance. The base 130c has a wire outlet slot 1302 to accommodate the lead wire 220, preventing the punch 140 from compressing the coil 210 with excessive pressure, which could damage the insulation layer of the lead wire 220. The contact surface 1301 of the base 130c is partially inclined to form a ramp 1303, which increases the space on the upper surface of the pressure block 132 to reduce pressure. This does not affect assembly and can also reduce the probability of insulation damage.

[0078] Third Embodiment

[0079] like Figures 16 to 19 As shown, the decoupling mechanism 150d includes at least one inclined surface 151d, which is disposed inside the winding post 110d to divide the winding post 110d into two mutually sliding winding blocks 114, so that the coil 210 can slide off as the winding blocks 114 slide relative to each other.

[0080] The coil 210 has a trapezoidal ring structure, and multiple winding blocks 114 can be arranged along the height direction of the trapezoid of the coil 210. Since two adjacent winding blocks 114 can slide relative to each other, after the coil 210 is compressed, one winding block 114 slides relative to the other winding block 114 and slides out of the coil 210, so that the supporting force of the winding block 114 on the coil 210 is released, and the coil 210 can be removed.

[0081] like Figures 16 to 18 As shown, an inclined plane 151d is formed between two adjacent winding blocks 114, and the winding block 114 slides out of the coil 210 along the inclined plane 151d. The upper and lower bottom surfaces of the winding block 114 are both horizontal planes, and the inclined plane 151d is inclined relative to the horizontal plane. By setting the inclined plane 151d, the winding block 114 can slide along the inclined plane.

[0082] like Figures 16 to 18 As shown, the winding post 110d also includes a fixing component 115, which is connected between two adjacent winding blocks 114.

[0083] Specifically, the fixing component 115 includes a fixing block 1151 and a connector 1152. The connector 1152 passes through the fixing block 1151 and is screwed onto one of the winding blocks 114. The fixing block 1151 is respectively engaged between two adjacent winding blocks 114. The connector 1152 can be a screw, see reference. Figure 16 The connector 1152 is screwed onto the winding block 114 on the left side. When the connector 1152 is released, the winding block 114 on the right side can move upward relative to the winding block 114 on the left side, so that the winding block 114 on the right side can slide out of the coil 210, so that the coil 210 can be removed.

[0084] like Figure 16 and Figure 17 As shown, the fixing components 115 are respectively embedded inside two adjacent winding blocks 114. A recess 117 is formed between the two adjacent winding blocks 114 so that the fixing components 115 are hidden in the recess 117, preventing the fixing components 115 from protruding and causing an increase in volume, and preventing them from affecting the stacking between the multiple coil compression units 100d. In addition, the head of the connector 1152 is also hidden inside the fixing block 1151.

[0085] like Figure 18 As shown, the base 130d has an abutment surface 1301 for the coil 210 to abut, and a wire outlet groove 1302 is provided on the abutment surface 1301.

[0086] The lead-out groove 1302 is located on the upper surface of the base 130d. The lead-out groove 1302 and the lead wire 220 of the coil 210 are opposite each other, so that the lead wire 220 is located inside the lead-out groove 1302, preventing the punch 140 from compressing the coil 210 with excessive pressure and damaging the insulation layer of the lead wire 220. The lead wire 220 extends from the bottom of the trapezoid of the coil 210, and the lead-out groove 1302 is located at the bottom of the trapezoid of the base 130d.

[0087] Continue to refer to Figure 3The contact surface 1301 is partially inclined to form a ramp 1303, which increases the space on the upper surface of the base 130d to reduce pressure, without affecting assembly, and also reduces the probability of insulation damage. Specifically, the ramp 1303 is located on the contact surface 1301 corresponding to the bottom of the trapezoid of the base 130d, which corresponds to the position where the coil 210 exits, that is, the exit groove 1302 is located on the ramp 1303. Of course, the ramp 1303 can also be located on the contact surface 1301 corresponding to the top of the trapezoid of the base 130d, or simultaneously on the contact surfaces 1301 corresponding to both the top and bottom of the trapezoid of the base 130d.

[0088] refer to Figure 9 , Figure 16 and Figure 17 The coil compression unit 100d further includes a housing 120, which is disposed around the winding post 110d to form a compression space 1001 between the housing 120 and the winding post 110d. The punch 140 is slidably connected within the compression space 1001. The contents of the housing 120 can be referred to in the second embodiment, and will not be described in detail here.

[0089] In summary, since adjacent winding blocks 114 can slide relative to each other, after the coil 210 is compressed, one winding block 114 slides relative to the other winding block 114 and slides out of the coil 210, thereby relieving the supporting force of the winding block 114 on the coil 210 and allowing the coil 210 to be removed. The outer shell 120 and the winding post 110d compress the inner and outer sides of the coil 210, while the punch 140 and the base 130d compress the upper and lower end faces of the coil 210, further improving the utilization rate of the slot space and thus enhancing heat dissipation performance. The base 130d has a wire outlet slot 1302 to accommodate the lead wire 220, preventing the punch 140 from compressing the coil 210 with excessive pressure and damaging the insulation layer of the lead wire 220. The contact surface 1301 of the base 130d is partially inclined to form a ramp 1303, which increases the space on the upper surface of the pressure block 132 to reduce pressure, without affecting assembly, and at the same time reduces the probability of insulation damage.

[0090] like Figures 1 to 7As shown, the coil compression fixture includes multiple coil compression units 100a-100d as described in the above embodiments, and the multiple coil compression units 100a-100d provide compression for each integrally wound coil. Since the coil compression fixture uses the coil compression units 100a-100d as described in the above embodiments, the beneficial effects of the coil compression fixture are the same as those of the coil compression units 100a-100d as described in the above embodiments. A compression space 1001 is formed between the winding posts 110a-110d and the outer casing 120 to compress the coil 210. By providing a wire outlet hole 1002 connecting the compression space 1001 and the outside, a wire 220 integrally wound and located between two adjacent coils 210 is led out. Multiple integrally wound coils 210 are compressed together. Compared with the existing technology of compressing one by one, the subsequent welding step between coils 210 is omitted, thereby effectively improving the winding forming efficiency. In addition, the coil compression unit 100a-100d compresses the coil 210, discharges the air between the coils, improves the utilization rate of the slot space, and thus improves the heat dissipation performance.

[0091] During winding, multiple coils 210 can be integrally wound using enameled wire, and a connector 200 integrally connected between two adjacent coils 210 can be referenced. Figure 8 Then, the wiring 200 is placed in the outlet hole 1002 of each of the coil compression units 100a-100d, and the coils 210 are compressed together using the multiple compression spaces 1001 of the coil compression units 100a-100d. Of course, the winding and compression of the coils 210 can be performed simultaneously. For example, after the enameled wire is wound into a coil 210 in the compression space 1001, the coil compression units 100a-100d compress the wound coil 210, and the enameled wire is led out from the outlet hole 1002 to the next compression space 1001 to wind and compress the coil 210. This process is repeated to form multiple coils 210 that are compressed and wound integrally.

[0092] like Figure 1 As shown, multiple coil compression units 100a are stacked from bottom to top. That is, after the coil 210 is placed in the compression space 1001 of the current coil compression unit 100a for compression, another coil compression unit 100a is placed on the current coil compression unit 100a to compress another coil 210, so that multiple coil compression units 100a are stacked. The coil compression units 100a can be transported by a robotic arm, and the stacked coil compression units 100a can be fixed by corresponding brackets to prevent tipping during the stacking process.

[0093] The outer casing 120 can abut against the base 130a of the current coil compression unit 100a and the base 130a of the previous coil compression unit 100a, that is, the outer casing 120 abuts against the base plates 131 of two adjacent coil compression units 100a.

[0094] Specifically, the base 130a includes a base plate 131, and the winding post 110a is fixed to the base plate 131. The two can be integrally formed. (See reference) Figures 2 to 6 The base plate 131 and the outer shell 120 are approximately the same size, so that the outer shell 120 can abut between the base plates 131 of two adjacent coil compression units 100a, wherein the base plate 131 and the outer shell 120 may be rectangular, but are not limited thereto.

[0095] like Figure 3 As shown, the base 130a also includes a pressure block 132, which surrounds the winding post 110a and is disposed on the base plate 131, so that the coil 210 is compressed between the pressure block 132 and the punch 140.

[0096] The pressure block 132, the compression space 1001, the punch 140, and the winding post 110a are respectively adapted to the shape of the coil 210, for reference. Figures 2 to 6 The coil 210 has a trapezoidal annular structure, and the lead wire 220 extends from the bottom of the trapezoid of the coil 210. It can be seen that the pressure block 132, the compression space 1001, and the punch 140 all have trapezoidal annular structures, while the cross-section of the winding post 110a can be trapezoidal; it is a solid structure to ensure the strength of the winding post 110a and extend its service life.

[0097] When the outer casing 120 is placed around the winding post 110a and abuts against the base plate 131, the pressure block 132 is located at the bottom of the compression space 1001 formed between the winding post 110a and the outer casing 120, wherein the height of the winding post 110a is higher than the height of the pressure block 132, so that the coil 210 wound on the winding post 110a can be compressed by the pressure block 132 and the punch 140. Furthermore, the height of the winding post 110a is approximately equal to that of the outer casing 120, so that the upper surface of the winding post 110a and the upper surface of the outer casing 120 can be flush, allowing another coil compression unit 100a to be placed on the upper surface of the outer casing 120.

[0098] In a preferred embodiment, the punch 140 of the current coil compression unit 100a is integrally formed with the base 130a of the previous coil compression unit 100a. Figure 5 and Figure 6 As shown, the punch 140 is fixed to the bottom of the base plate 131, while the winding post 110a and the pressure block 132 are disposed on the top of the base plate 131. Thus, after the coil 210 is placed on the winding post 110a and the outer shell 120 is placed on the base plate 131, the base plate 131 of another coil compression unit 100a can be placed on the outer shell 120 of the current coil compression unit 100a. The punch 140 of the other base plate 131 can then compress the current coil 210, making the structure more compact. After stacking, multiple coils can be compressed together using a stamping device, thereby improving the compression efficiency.

[0099] like Figure 3 As shown, the pressure block 132 has an abutting surface 1301 that abuts against the coil 210. A wire outlet groove 1302 is provided on the abutting surface 1301, and the wire outlet groove 1302 corresponds to the wire outlet hole 1002 on the outer casing 120.

[0100] The contact surface 1301 of the pressure block 132 is located on the upper end face of the pressure plate 132 away from the base plate 131. The lead-out groove 1302 and the lead wire 220 of the coil 210 are opposite each other, so that the lead wire 220 is located in the lead-out groove 1302, preventing the punch 140 from compressing the coil 210 with excessive pressure and damaging the insulation layer of the lead wire 220. The lead wire 220 is led out from the bottom of the trapezoid of the coil 210, and the lead-out groove 1302 is located at the bottom of the trapezoid of the pressure block 132.

[0101] Continue to refer to Figure 3 The contact surface 1301 is partially inclined to form a ramp 1303, which increases the space on the upper surface of the pressure block 132 to reduce pressure. This does not affect assembly and also reduces the probability of insulation damage. Specifically, the ramp 1303 is located on the contact surface 1301 corresponding to the bottom of the trapezoid of the pressure block 132. This position corresponds to the position where the coil 210 leads out, that is, the lead-out groove 1302 is located on the ramp 1303. Of course, the ramp 1303 can also be located on the contact surface 1301 corresponding to the top of the trapezoid of the pressure block 132, or simultaneously on the contact surfaces 1301 corresponding to both the top and bottom of the trapezoid of the pressure block 132.

[0102] In addition, the ramp 1303 can also be located on the lower surface of the punch 140, corresponding to the abutment surface 1301 corresponding to the trapezoidal top and / or bottom of the punch 140. This can also reduce pressure, protect the coil insulation, and not affect assembly.

[0103] In summary, by providing a lead-out hole 1002 connecting the compression space 1001 and the outside, a lead-out wire 220 integrally wound and located between two adjacent coils 210 is led out. Multiple integrally wound coils 210 are compressed together, eliminating the need for subsequent welding between coils 210 compared to the prior art's method of compressing them one by one. This effectively improves the winding forming efficiency. Furthermore, the coil compression unit 100a compresses the coils 210, expelling air between the coils and improving the utilization rate of the slot space, thereby enhancing heat dissipation performance. The punch 140 and the base plate 131 are integrally formed, making the structure more compact, further improving forming efficiency and reducing costs. The pressure block 132 of the base 130a has a lead-out slot 1302 to accommodate the lead-out wire 220, preventing excessive pressure from the punch 140 compressing the coils 210 and damaging the insulation layer of the lead-out wire 220. The contact surface 1301 is partially inclined to form a ramp 1303, which increases the space on the upper surface of the pressure block 132 to reduce pressure. This does not affect assembly and can also reduce the probability of insulation damage.

[0104] like Figures 1 to 19 As shown, the present invention also provides a coil compression method, comprising the following steps:

[0105] S100, coil 210 is arranged on winding posts 110a to 110d;

[0106] S200, a housing 120 with a wire outlet 1002 is provided, the housing 120 is fixed to the periphery of the coil 210, and the lead wire 220 connected to the end of the coil 210 is led out from the wire outlet 1002 in a non-bending manner;

[0107] S300, the punch 140 is slid between the winding posts 110a-110d and the outer casing 120 to compress the coil 210;

[0108] S400, remove the punch 140 and the outer casing 120, and separate the compressed coil 210 and the winding posts 110a to 110d by the wire removal mechanism 150b to 150d.

[0109] In step S100, the wound coil 210 can be arranged on the winding posts 110a to 110d. Of course, enameled wire can be used to wind the winding posts 110a to 110d to form the coil 210, which will be compressed in subsequent steps.

[0110] In step S200, excessive bending of the lead wire 220 is prevented from damaging its insulation layer, thereby extending its service life.

[0111] In step S300, the punch 140 can use a stamping device to compress the coil 210, wherein the outer shell 120 and the winding post 110b compress the inner and outer sides of the coil 210, while the punch 140 and the base 130b compress the upper and lower end faces of the coil 210, further improving the utilization rate of the slot space and thus improving the heat dissipation performance.

[0112] In step S400, as Figures 9 to 13 As shown, the wire-removing mechanism 150b includes at least one inclined surface 151b, which is disposed on the outer surface of the winding post 110b, and then in step S400, the coil 210 slides away along the inclined surface 151b.

[0113] like Figure 14 and Figure 15 As shown, the unwinding mechanism 150c includes at least one set screw hole 113. The bottom of the winding post 110c extends outward to form an extension body 112. The set screw hole 113 is disposed on the extension body 112. Then, in step S400, the coil 210 is slid away by passing the set screw tool through the set screw hole 113.

[0114] like Figures 16 to 19 As shown, the decoupling mechanism 150d includes at least one inclined surface 151d, which is disposed inside the winding post 110d to divide the winding post 110d into two mutually sliding winding blocks 114. Thus, in step S400, the coil 210 slides away as the winding blocks 114 slide relative to each other.

[0115] The compressed coil 210 can be separated from the winding posts 110a to 110d by the wire removal mechanism 15d, to prevent the coil 210 and the winding posts 110a to 110d from being too tightly bound together and unable to remove the wire, and to prevent improper wire removal operation from affecting the state of the compressed coil 210 and avoiding compression failure.

[0116] The embodiments described above are only used to illustrate the technical ideas and features of the present invention. Their purpose is to enable those skilled in the art to understand the content of the present invention and implement it accordingly. The scope of patent application of the present invention should not be limited by these embodiments. That is, any equivalent changes or modifications made in accordance with the spirit disclosed in the present invention still fall within the patent scope of the present invention.

Claims

1. A coil compression tooling, characterized in that, It includes multiple coil compression units (100a~100d), which provide compression for each integrally wound coil, and the multiple coil compression units (100a) are stacked from bottom to top; The coil compression unit (100a~100d) includes a winding post (110a~110d), a housing (120), a base (130a~130d), a punch (140), and a wire removal mechanism (150b~150d). The winding post (110a~110d) is disposed on the base (130a~130d), and the coil (210) is detachably arranged on the winding post (110a~110d). The housing (120) surrounds the coil (210), and the punch (140) can slide between the winding post (110a~110d) and the housing (120) to compress the coil (210). The wire removal mechanism (150b~150d) is used to separate the compressed coil (210) from the winding post (110a~110d). The base (130a) includes a base plate (131), the winding post (110a) is fixed on the base plate (131), and the outer shell (120) abuts between the base plates (131) of two adjacent coil compression units (100a); The base (130a) further includes a pressure block (132), which is disposed on the base plate (131) and located between the winding post (110a) and the outer shell (120) so that the coil (210) is compressed between the pressure block (132) and the punch (140); The punch (140) is fixed to the bottom of the base plate (131), and the winding post (110a) and the pressure block (132) are disposed on the top of the base plate (131).

2. The coil compression fixture as described in claim 1, characterized in that, The punch (140) of the coil compression unit (100a) is integrally formed with the base (130a) of the previous coil compression unit (100a).

3. The coil compression fixture as described in claim 1, characterized in that, The wire-removing mechanism (150b) includes at least one inclined surface (151b) disposed on the outer surface of the winding post (110b) so that the coil (210) can slide off along the inclined surface (151b).

4. The coil compression fixture as described in claim 1, characterized in that, The unwinding mechanism (150c) includes at least one set screw hole (113), and the bottom of the winding post (110c) extends outward to form an extension body (112), and the set screw hole (113) is disposed on the extension body (112).

5. The coil compression fixture as described in claim 1, characterized in that, The decoupling mechanism (150d) includes at least one inclined surface (151d) disposed inside the winding post (110d) to divide the winding post (110d) into two mutually sliding winding blocks (114) so ​​that the coil (210) can slide off as the winding blocks (114) slide against each other.

6. The coil compression fixture as described in claim 1, characterized in that, The housing (120) is provided with a wire outlet hole (1002) corresponding to the end of the coil (210) so that the lead wire (220) connected to the end of the coil (210) is led out from the wire outlet hole (1002) in a non-bending manner.

7. The coil compression fixture as described in claim 6, characterized in that, The base (130a~130d) has an abutting surface (1301) that abuts against the lower end face of the coil (210). The abutting surface (1301) is provided with a wire outlet groove (1302) for accommodating the lead wire (220). The wire outlet groove (1302) extends in a straight line between the end of the coil (210) and the wire outlet hole (1002).

8. The coil compression fixture as described in claim 7, characterized in that, The lower surface portion of the contact surface (1301) or the punch (140) is inclined to form a ramp (1303).

9. A coil compression method using a coil compression fixture as described in any one of claims 1 to 8, characterized in that, Includes the following steps: S100, the coil (210) is arranged on the winding post (110a~110d); S200, a housing (120) with a wire outlet (1002) is provided, the housing (120) is fixed to the periphery of the coil (210), and the lead wire (220) connected to the end of the coil (210) is led out from the wire outlet (1002) in a non-bending manner; S300, the punch (140) is slid between the winding post (110a~110d) and the housing (120) to compress the coil (210); S400, remove the punch (140) and the housing (120), and separate the compressed coil (210) and the winding post (110a~110d) by the wire removal mechanism (150b~150d).

10. The coil compression method as described in claim 9, characterized in that, The wire-removing mechanism (150b) includes at least one inclined surface (151b) which is disposed on the outer surface of the winding post (110b), and then in step S400, the coil (210) slides away along the inclined surface (151b).

11. The coil compression method as described in claim 9, characterized in that, The wire-removing mechanism (150c) includes at least one set screw hole (113), and the bottom of the winding post (110c) extends outward to form an extension body (112). The set screw hole (113) is disposed on the extension body (112), and then in step S400, the coil (210) is slid away by passing a set screw tool through the set screw hole (113).

12. The coil compression method as described in claim 9, characterized in that, The decoupling mechanism (150d) includes at least one inclined surface (151d) disposed inside the winding post (110d) to divide the winding post (110d) into two mutually sliding winding blocks (114), thereby in step S400, the coil (210) slides away as the winding blocks (114) slide relative to each other.

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