A winding device and winding method for a motor stator coil

Abstract

The invention discloses a winding device and a winding method for a motor stator coil. The winding device is characterized by: an upper wire pressing rod movement mechanism (1) for pressing a wire rod; a lower wire pressing rod movement mechanism (2) for pressing a wire rod; a spindle movement mechanism (3) for pulling a wire rod to wind a coil on a motor stator core (40); a motor stator core positioning and locking mechanism (4); a gantry (B); and a base A on which the gantry (B), the upper wire pressing rod movement mechanism (1), the lower wire pressing rod movement mechanism (2), the spindle movement mechanism (3), and the motor stator core positioning and locking mechanism (4) are fixedly mounted. The winding device and the winding method can achieve a method in which a wire nozzle does not enter a tooth slot of a brushless motor stator to wind a coil.

Description

Technical Field

[0001] The present invention relates to the technical field of winding coils on a brushless motor stator core, and in particular to a winding device and a winding method for winding coils outside a brushless motor stator slot. Background Art

[0002] Currently, there are two known technical methods for winding the stator of a brushless motor: one is to enter the slots between the stator teeth through a wire nozzle and wind the wire around the stator tooth core; the other is to make a circular motion around the tooth core through the wire nozzle, and slide the wire into the slots between the teeth through auxiliary mechanisms such as protective plates.

[0003] The wire is wound around the stator tooth core through the wire nozzle entering the slot between the stator teeth. This winding technology is generally used in the field of coil winding on the closed brushless motor stator. The disadvantage is that since the wire nozzle takes up a part of the space when entering the slot between the teeth, it is required to reserve space for the wire nozzle to move when designing the motor stator. This results in the slot between the motor stator teeth to be large enough, thereby increasing the size of the motor. When the slot between the motor stator teeth is small, the number of turns of the winding wire will be small or the slot fill rate (slot fill rate refers to the volume occupied by the wire in the slot between the teeth) will be too low, resulting in reduced motor performance.

[0004] The wire is made to move in a circular motion around the tooth core by the wire nozzle, and the wire is slid into the inter-tooth slot by auxiliary mechanisms such as guard plates. This winding technology is usually used in the field of coil winding on the unfolded brushless motor stator. The disadvantages are: the wire diameter is generally not more than 0.1mm, and the wire is easily damaged when the wire slides into the wire slot; since auxiliary mechanisms such as guard plates need to enter the inter-tooth slot and occupy a part of the space, the motor stator design requires to reserve space for the movement of auxiliary mechanisms such as guard plates, which results in the inter-tooth slot of the motor stator to be large enough, thereby increasing the size of the motor. When the inter-tooth slot of the motor stator is small, the number of winding turns will be small or the slot fill rate will be too low, resulting in reduced motor performance. Summary of the Invention

[0005] The purpose of the present invention is to provide a winding device and a winding method in which the wire nozzle does not enter the slots between the teeth of the motor stator, in response to the current state of the art. The advantages of the present invention are that the number of turns of the motor stator coil can be greatly increased, especially the number of turns of the coil wound in the small slots between the teeth, without damaging the wire.

[0006] According to the technical method of the present invention, the winding device for winding the coil is: an upper wire pressing rod movement mechanism, which guides and controls the position of the wire above the motor stator tooth core, and moves in three directions: left and right, front and back, and up and down, and moves as the position of the coil turns changes; a lower wire pressing movement mechanism, which guides and controls the position of the wire below the motor stator tooth core, and moves in three directions: left and right, front and back, and up and down, and moves as the position of the coil turns changes; a spindle movement mechanism, which pulls the wire through the wire nozzle to move in three directions: left and right, front and back, and up and down; a motor stator core positioning and locking mechanism, which positions and fixes the motor stator core so that its position is accurate and its state is stationary.

[0007] According to the technical solution of the present invention, the winding method for winding the coil turns is as follows: the wire passes through the inner cavity of the wire nozzle, and the wire nozzle pulls the wire to move. Initially, the wire nozzle pulls the wire to the right root of the upper surface of the stator tooth core. The upper wire pressing rod presses the wire. The wire nozzle moves backward horizontally to the outside of the top of the stator tooth core. The wire nozzle moves downward vertically to the lower surface of the stator tooth core. The wire nozzle moves forward horizontally along the lower surface to the root of the stator tooth core. The wire nozzle moves horizontally to the left along the lower surface to the left of the root of the stator tooth core. The lower wire pressing rod presses the wire. The wire nozzle moves backward horizontally to the outside of the top of the stator tooth core. The wire nozzle moves upward vertically to the upper surface of the stator tooth core. The wire nozzle moves forward horizontally along the upper surface of the tooth core to the root of the stator tooth core. The wire nozzle moves horizontally to the right along the upper surface of the tooth core to the right of the root of the stator tooth core. The upper wire pressing rod presses the wire, completing the winding action of one turn of the coil. Repeat the above winding method to complete the winding of the specified number of turns of a tooth core and the winding of a complete motor stator coil. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 This is the main structure diagram of the winding device of the present invention

[0009] Figure 2 This is a structural diagram of the upper thread pressing rod movement mechanism of the present invention

[0010] Figure 3 This is a structural diagram of the lower thread pressing rod movement mechanism of the present invention

[0011] Figure 4 This is a structural diagram of the spindle motion mechanism of the present invention

[0012] Figure 5 This is a schematic diagram of the structure of an expanded motor stator core introduced in this invention.

[0013] Figure 6 The process step 1 of the winding method of the present invention is

[0014] Figure 7This is the process step 2 of the winding method of the present invention.

[0015] Figure 8 This is the process step 3 of the winding method of the present invention.

[0016] Figure 9 This is the process step 4 of the winding method of the present invention.

[0017] Figure 10 This is the process step 5 of the winding method of the present invention.

[0018] Figure 11 This is the process step 6 of the winding method of the present invention.

[0019] Figure 12 This is the process step 7 of the winding method of the present invention.

[0020] Figure 13 This is the process step 8 of the winding method of the present invention.

[0021] Figure 14 This is the process step 9 of the winding method of the present invention.

[0022] Figure 15 This is a schematic diagram of the closed brushless motor stator core pattern 1 involved in the present invention

[0023] Figure 16 This is a schematic diagram of the closed brushless motor stator core style 2 involved in the present invention DETAILED DESCRIPTION

[0024] The specific embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0025] Figure 1 The main structure diagram of the winding device provided by the present invention is shown, which mainly includes an upper wire pressing rod movement mechanism 1, on which there are three movement drive mechanisms 11 to 13 ( Figure 2 As shown), it is used to drive the upper pressing rod 10 to move in the three directions of X, Y and Z axes; the lower pressing rod movement mechanism 2 has three movement drive mechanisms 21 to 23 ( Figure 3 As shown), it is used to drive the lower wire pressing rod 20 to move in the three directions of X, Y and Z axes; the main shaft movement mechanism 3 has three movement drive mechanisms 31 to 33 ( Figure 4 As shown), it is used to drive the wire nozzle 30 to move in the three directions of X, Y and Z axes. The wire nozzle 30 has a built-in center hole, and the wire 50 passes through the center hole ( Figure 6 As shown); the motor stator core positioning locking mechanism 4, positioning and fixing the motor stator core 40 ( Figure 5As shown in the figure), its position is accurate and its state is stationary; the gantry B has an upper wire pressing rod motion mechanism 1 on it; the integral base A is used to install and fix the gantry B, the lower wire pressing rod motion mechanism 2, the spindle motion mechanism 3 and the motor stator core positioning and locking mechanism 4.

[0026] Figure 2 The figure shows an upper wire pressing rod movement mechanism 1, which is mainly provided with an upper wire pressing rod 10, a first X-axis drive mechanism 11, a first Y-axis drive mechanism 12 and a first Z-axis drive mechanism 13, wherein the drive mechanisms 11, 12 and 13 are orthogonal to each other, driving the upper wire pressing rod 10 to move along the X, Y and Z axes on the upper side of the stator core 40. In this device, the X axis is set as the axis moving along the left and right directions, the Y axis is set as the axis moving along the front and rear directions, and the Z axis is set as the axis moving along the up and down directions.

[0027] Figure 3 The figure shows the lower wire pressing rod movement mechanism 2, which is mainly provided with a lower wire pressing rod 20, a second X-axis drive mechanism 21, a second Y-axis drive mechanism 22 and a second Z-axis drive mechanism 23, wherein the drive mechanisms 21, 22 and 23 are orthogonal to each other, driving the upper wire pressing rod 20 to move along the X, Y and Z axes on the lower side of the stator core 40. The device sets the X axis as the axis moving along the left and right directions, the Y axis as the axis moving along the front and rear directions, and the Z axis as the axis moving along the up and down directions.

[0028] Figure 4 The main spindle motion mechanism 3 is shown, which is mainly provided with a wire nozzle 30, a third X-axis drive mechanism 31, a third Y-axis drive mechanism 32 and a third Z-axis drive mechanism 33. The drive mechanisms 31, 32 and 33 are orthogonal to each other, pulling the wire nozzle 30 to move in the three directions of X, Y and Z axes. In this device, the X axis is set as the axis moving along the left and right directions, the Y axis is set as the axis moving along the front and rear directions, and the Z axis is set as the axis moving along the up and down directions.

[0029] Figure 5 The stator core (hereinafter referred to as the stator) 40 of the unfolded brushless motor introduced in the present invention has a tooth core (hereinafter referred to as the tooth core) 41, a slot between teeth (hereinafter referred to as the tooth slot) 42, a tooth core root (hereinafter referred to as the tooth root) 43, a tooth core top (hereinafter referred to as the tooth top) 44, a tooth core left side 45, and a tooth core right side 46.

[0030] Figures 6 to 14 The stator winding method of the present invention has the following process:

[0031] In the first step, the wire nozzle 30 pulls the wire 50 to move Figure 6 At the tooth root 43bc position on the right side 46bc of the stator tooth core 41c, the upper wire pressing rod 10 moves downward along the Z axis and stops after pressing the wire 50, and the wire nozzle 30 pulls the wire 50 and moves backward along the Y axis to Figure 7The outer side of the tooth top 44c of the stator tooth core 41c is shown;

[0032] The second step is Figure 8 As shown, the wire nozzle 30 pulls the wire 50 from the tooth groove 42bc and moves downward along the Z axis to reach Figure 9 The upper wire pressing rod 10 moves upward along the Z axis to separate from the wire;

[0033] In the third step, the wire nozzle 30 pulls the wire 50 to the left along the X axis. Figure 10 In the position shown, the lower wire pressing rod 20 moves upward along the Z axis and stops after pressing the wire 50;

[0034] Step 4: The wire nozzle 30 pulls the wire 50 and moves backward along the Y axis to Figure 11 The outer side of the tooth top 44c of the stator tooth core 41c is shown;

[0035] Step 5: Figure 12 As shown, the wire nozzle 30 pulls the wire 50 from the tooth groove 42cd and moves upward along the Z axis to reach Figure 13 Position shown;

[0036] Step 6: The wire nozzle 30 pulls the wire 50 to the right along the X axis to Figure 14 In the position shown, the upper wire pressing rod 10 moves downward along the Z axis and stops after pressing the wire 50; at the same time, the lower wire pressing rod 20 moves downward along the Z axis to separate from the wire; the winding of one turn of the coil is completed.

[0037] In the seventh step, the upper pressing rod 10 and the lower pressing rod 20 move forward and backward along the Y axis, and repeat the first to sixth steps to complete the multi-turn and multi-layer winding of a tooth core;

[0038] The upper wire pressing rod 10 and the lower wire pressing rod 20 move left and right along the X axis, and the first to seventh steps are repeated to complete the winding of multiple tooth cores of a stator.

[0039] The winding method of the present invention is fully applicable to Figure 15 The outer wound stator 60 shown and Figure 16 The coil windings of the inner wound stator 70 are shown.

[0040] In summary, the detailed description of the embodiments of the present invention only illustrates a part of the application method of the present invention, rather than limiting it. Various changes or modifications made by ordinary technicians in this field will not depart from the scope of the present invention.

Claims

1. A brushless motor stator coil winding device, characterized in that: An upper wire pressing rod movement mechanism (1) for pressing the wire (50); A lower wire pressing rod movement mechanism (2) for pressing the wire material (50); A spindle motion mechanism (3) is used to pull a wire (50) to form a coil on the motor stator core (40); A motor stator core positioning and locking mechanism (4) for positioning and fixing the motor stator core (40); a gantry (B) on which an upper wire pressing rod movement mechanism (1) is mounted; The integral base (A) is used to install and fix the gantry (B), the upper wire pressing rod movement mechanism (1), the lower wire pressing rod movement mechanism (2), the main shaft movement mechanism (3) and the motor stator core positioning and locking mechanism (4); The upper wire pressing rod movement mechanism (1) comprises an upper wire pressing rod (10), a first X-axis driving mechanism (11), a first Y-axis driving mechanism (12) and a first Z-axis driving mechanism (13), and the first X-axis driving mechanism (11), the first Y-axis driving mechanism (12) and the first Z-axis driving mechanism (13) are orthogonal to each other, and the first X-axis driving mechanism (11), the first Y-axis driving mechanism (12) and the first Z-axis driving mechanism (13) respectively drive the upper wire pressing rod (10) to move along the three directions of the X, Y and Z axes on the upper side of the stator core (40); The lower wire pressing rod movement mechanism (2) comprises a lower wire pressing rod (20), a second X-axis driving mechanism (21), a second Y-axis driving mechanism (22) and a third Z-axis driving mechanism (23), and the second X-axis driving mechanism (21), the second Y-axis driving mechanism (22) and the third Z-axis driving mechanism (23) are orthogonal to each other, and the second X-axis driving mechanism (21), the second Y-axis driving mechanism (22) and the third Z-axis driving mechanism (23) respectively drive the lower wire pressing rod (20) to move along the three directions of the X, Y and Z axes on the lower side of the stator core (40); The spindle motion mechanism (3) includes a wire nozzle (30), a third X-axis drive mechanism (31), a third Y-axis drive mechanism (32) and a third Z-axis drive mechanism (33), and the third X-axis drive mechanism (31), the third Y-axis drive mechanism (32) and the third Z-axis drive mechanism (33) are orthogonal to each other. The third X-axis drive mechanism (31), the third Y-axis drive mechanism (32) and the third Z-axis drive mechanism (33) respectively drive the wire nozzle (30) to move in the three directions of the X, Y and Z axes, and the wire nozzle (30) is used to pull the wire (50).

2. A brushless motor stator coil winding device according to claim 1, characterized in that: The brushless motor stator coil winding device is fully applicable to coil winding of an outer-wound stator (60) and an inner-wound stator (70).

3. A brushless motor stator coil winding method, using the brushless motor stator coil winding device according to claim 1, characterized in that: The wire nozzle (30) pulls the wire (50) to the tooth root (43bc) position on the right side (46bc) of the stator tooth core (41c), the upper wire pressing rod (10) moves downward along the Z axis and stops after pressing the wire (50), and the wire nozzle (30) pulls the wire (50) and moves backward along the Y axis to the outside of the tooth top (44c) of the stator tooth core (41c); The wire nozzle (30) pulls the wire (50) from the tooth groove (42bc) and moves downward along the Z axis. After the wire nozzle pulls the wire (50) to the bottom of the tooth root (43bc), the upper wire pressing rod (10) moves upward along the Z axis to separate from the wire; The wire nozzle (30) pulls the wire (50) to move leftward along the X-axis to the left side of the stator tooth core (41c), and the lower wire pressing rod (20) moves upward along the Z-axis to press the wire (50) and then stops; The wire nozzle (30) pulls the wire (50) and moves it backward along the Y axis to the outside of the tooth top (44c) of the stator tooth core (41c); The wire nozzle (30) pulls the wire (50) from the tooth slot (42cd) upward along the Z axis to reach above the stator tooth core (41c); The wire nozzle (30) pulls the wire (50) to move rightward along the X-axis to reach the right side (46bc) of the stator tooth core (41c), and the upper wire pressing rod (10) moves downward along the Z-axis and stops after pressing the wire (50); at the same time, the lower wire pressing rod (20) moves downward along the Z-axis to separate from the wire; the winding of one turn of the coil is completed.

4. The brushless motor stator coil winding method according to claim 3, characterized in that: Repeating the winding method described in claim 3, the upper wire pressing rod motion mechanism, the lower wire pressing rod motion mechanism and the main shaft motion mechanism respectively move in the left and right, front and back and up and down directions, and move their positions according to the changes in the number of coil turns; completing multi-turn and multi-layer winding of a tooth core and winding of multiple tooth cores of a stator.

5. A brushless motor stator coil winding method according to any one of claims 3-4, characterized in that: The winding method is fully applicable to the coil winding of an outer-wound stator (60) and an inner-wound stator (70).

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