Flat wire guiding and take-up mechanism for electric machines and design method for the guiding groove thereof

Abstract

The application discloses a flat wire motor guide take-up mechanism and a design method of a guide groove thereof, relates to the technical field of flat wire motor plug-in assembly, and is composed of a supporting plate, inner and outer layer motors, an inner rotating disc, a guide disc and a push rod, the guide groove in the guide disc is calculated, a same rotating speed relationship formula of the guide disc and the inner layer motor is obtained according to a relationship formula of a change angle alpha of the inner layer motor and a centripetal feeding distance S of the push rod, and then the rotating speed of the inner and outer layer motors is matched. The application can realize rapid calculation according to motors of different models, generate a curve through batch coordinate points, achieve a required guide groove curve, and then is manufactured through a machining center to generate a transmission ratio of the inner and outer layer motors, thereby greatly reducing subsequent electrical debugging time, greatly improving debugging efficiency, saving design time, and upgrading related production lines through the structure and method, and improving production precision and quality.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of flat wire motor plug-in assembly, in particular to a flat wire guiding and winding mechanism of a motor and a design method of a guide groove thereof. BACKGROUND

[0002] In the process step of winding of the hairpin type flat wire motor, the batch of hairpin type flat wires is shaped and then inserted into the stator core slot, and the current winding basically uses a guide groove shape. For example, in the patent CN202120807723.8, a kind of flat wire motor copper wire automatic assembly device, the rotating speed of the two motors sometimes does not match when the winding device works, the speed of the two wire feet of the copper wire shrinking inward is inconsistent, which finally leads to unstable winding, unevenness, and affects the subsequent plug-in accuracy. The second point is that the electrical debugging is very difficult, time-consuming and low in efficiency. The new production line will delay the construction period. According to the above-mentioned existing situation, the guide groove shape is researched and developed, and a set of guide wire mechanism and its guide groove design method are developed. SUMMARY

[0003] The purpose of the present application is to provide a flat wire guiding and winding mechanism of a motor and a design method of a guide groove thereof to solve the problems raised in the background art.

[0004] To achieve the above-mentioned purpose, the present application provides the following technical scheme: the shape of the guide groove is changed (according to the relationship between the change angle α of the inner motor and the distance S of the push rod centripetal feeding), so that the rotating speed of the guide disc and the inner motor is the same, and then the rotating speed of the inner and outer motors is matched.

[0005] A kind of flat wire motor guiding and winding mechanism is proposed, which comprises a support plate, the lower left side of the support plate is fixed with an outer motor, the head of the outer motor is provided with a pinion, the lower end of the support plate is fixed with an inner motor in the middle, the upper end of the inner motor is connected with an inner rotating disc, the upper end of the support plate is provided with a guide disc in the middle, the guide disc is uniformly distributed with guide grooves, the outer right side of the guide disc is provided with a transmission gear and is engaged with the pinion, a push rod is clamped between the support plate and the guide disc, a guide column is arranged at the rear of the push rod, and the guide column is inserted into the guide groove.

[0006] Further, the middle part of the support plate is symmetrically distributed with a strip-shaped groove, the lower part of the push rod is gap-fitted with the strip-shaped groove and can slide, and the front end of the push rod and the outer side of the inner rotating disc are both provided with a flat wire groove, and the inner and outer copper feet of the hairpin flat wire are respectively located in the flat wire grooves of the inner rotating disc and the push rod.

[0007] The design of the guide groove comprises the following steps:

[0008] Firstly, the relationship between the change angle α of the inner motor and the displacement S of the push rod is calculated.

[0009] The auxiliary parameters required include:

[0010] α - inner copper foot change angle;

[0011] S - outer copper foot feed distance;

[0012] r - inner diameter of copper wire;

[0013] a - copper wire span;

[0014] L1 - the vertical distance between the horizontal direction of the initial position of the inner copper foot to the center of the inner layer turntable;

[0015] L2 - the vertical distance between the horizontal direction of the end position of the inner copper foot to the center of the inner layer turntable;

[0016] L3 - the vertical distance between the horizontal direction of the initial and end positions of the inner copper foot;

[0017] L4 - the vertical distance between the horizontal direction of the end position of the outer copper foot and the end position of the inner copper foot;

[0018] L5 - the vertical distance between the horizontal direction of the initial position of the outer copper foot and the initial position of the inner copper foot;

[0019] L6 - the vertical distance between the horizontal direction of the end position of the outer copper foot and the initial position of the inner copper foot;

[0020] C1 - the vertical distance between the end position of the inner copper foot and the vertical center line of the inner layer turntable;

[0021] C2 - the vertical distance between the initial position of the inner copper foot and the vertical center line of the inner layer turntable;

[0022] α0 - the included angle between the initial position of the inner copper foot, the inner layer turntable, and the end position of the inner copper foot, i.e. the initial angle;

[0023] The following parameter calculations are performed:

[0024] L1 = r * COSα0

[0025] L2 = r * COS(α0 + α)

[0026] L3 = L1 - L2 = r * COSα0 - r * COS(α0 + α)

[0027] C1 = r * sin(α0 + α)

[0028]

[0029]

[0030]

[0031] The calculation result is:

[0032]

[0033] The formula relating α and S will be used in the following Excel spreadsheet formula for generating guide groove curves.

[0034] The second step involves machining the guide grooves on the guide plate using a machining center, requiring accurate 3D or 2D drawings. Based on the relationships derived in the first step, a Cartesian coordinate system is established in an Excel spreadsheet. The auxiliary parameters used include:

[0035] The total distance from the X-axis to the extended radius of one of the guide disks corresponding to angle M-α;

[0036] The distance from the intersection of the M1 guide groove curve and one of its radii to the X-axis along the radial direction;

[0037] Φ / 2 - Radius of the pitch circle at the starting point of the guide groove;

[0038] x-axis:

[0039] X=(φ / 2-S)*SINα

[0040] M=φ / 2 / COSα

[0041] M1=M-φ / 2+S

[0042] Vertical axis:

[0043] Y=M1*COSα=(M-φ / 2+S)*COSα

[0044] Using the above relationship, insert formulas into an Excel spreadsheet to perform waterfall-style calculations, obtaining multiple coordinate points; the more points, the smoother the result.

[0045] The third step is to use the coordinate system obtained in the second step to generate the guide groove curve in the CAD software to obtain a two-dimensional curve. Then, select the coordinate system in the organized EXCEL table, enter "PL" in the CAD text window, click "space", and then paste the coordinate system by "ctrl+V" in the text window. This will generate the guide groove curve.

[0046] Step 4: Export the 2D curve obtained in step 3 as a DXF file, drag it into 3D software to create a 3D model; import the DXF file into CATIA, copy the imported curve by CTRL+C, create a sketch in the guide plate part, paste it using CTRL+V, then switch to surface design, select the merging command, merge the curves to make them a continuous curve.

[0047] Step 5: Determine the relationship between the inner and outer motor speeds and generate a relationship curve. In step S5, when the guide groove on the guide plate is machined according to the calculated curve, the rotation angle of the inner motor is equal to the rotation angle of the guide plate. Then, the speed relationship between the outer motor ω1 and the inner motor ω2 is: ω1 / ω2 = number of teeth of the driven gear / number of teeth of the driving gear. Then, the pinion and transmission gear can be machined to realize the manufacturing of the part.

[0048] Step 6: Simulation verification and actual manufacturing. The results are verified by simulating the operation with 3D software. Then, the guide plate is manufactured by machining center, and the various parts are assembled to verify the actual effect.

[0049] Compared with the prior art, the beneficial effects of the present invention are: the present invention can quickly calculate according to different models of motors, generate curves through batch coordinate points to achieve the required guide groove curves, and then generate the transmission ratio of the inner and outer motors through machining center manufacturing, which can greatly reduce the subsequent electrical debugging time, greatly improve debugging efficiency, and save design time. Through this structure and method, related production lines can be upgraded and transformed to achieve improvements in production accuracy and quality. Attached Figure Description

[0050] Figure 1 This is a schematic diagram of the guiding and take-up mechanism of the present invention;

[0051] Figure 2 for Figure 1 Enlarged schematic diagram of the present invention at point A;

[0052] Figure 3 This is a front view schematic diagram of the guide plate of the present invention;

[0053] Figure 4 A schematic diagram showing the derivation of the formulas for the motor's changing angle α and the distance S of the push rod's centripetal feed.

[0054] Figure 5 Schematic diagram of the derivation of the rectangular coordinate system formula for the conductor groove curve;

[0055] Figure 6 This is a table showing examples of angle and distance change calculations for this invention.

[0056] Figure 7 This invention provides a CAD-generated curve coordinate example table;

[0057] Figure 8 This is a graph showing the relationship between the changing angle α and S in this invention.

[0058] Figure 9 This is an example diagram of the transmission ratio of the present invention.

[0059] In the diagram: 1. Support plate, 2. Outer motor, 3. Guide plate, 4. Inner motor, 5. Push rod, 6. Guide post, 7. Inner turntable, 8. Hairpin flat wire, 101. Strip groove, 301. Guide groove, 302. Transmission gear. Detailed Implementation

[0060] The invention will now be described in conjunction with the accompanying drawings of the embodiments. However, it is worth noting that the invention is not limited to these embodiments. In the following detailed description of the invention, some specific details are described in detail. However, those skilled in the art can fully understand the invention for the parts that are not described in detail.

[0061] Furthermore, those skilled in the art should understand that the accompanying drawings are provided only to illustrate the purpose, features, and advantages of the present invention, and are not actually drawn to scale.

[0062] Furthermore, unless the context explicitly requires it, the words "comprising," "including," and similar terms throughout the specification and claims should be interpreted as including rather than exclusive or exhaustive; that is, meaning "including but not limited to."

[0063] Please see Figures 1-7 The present invention provides a technical solution comprising: a support plate 1, an outer motor 2 fixed to the lower left side of the support plate 1, a small gear mounted on the head of the outer motor 2, an inner motor 4 fixed to the middle of the lower end of the support plate 1, an inner turntable 7 connected to the upper end of the inner motor 4, a guide plate 3 provided in the middle of the upper end of the support plate 1, guide grooves 301 evenly distributed on the guide plate 3, a transmission tooth 302 provided on the outer right side of the guide plate 3 and meshing with the small gear, a push rod 5 sandwiched between the support plate 1 and the guide plate 3, a guide post 6 provided behind the push rod 5 and inserted into the guide groove 301.

[0064] The support plate 1 has a strip groove 101 symmetrically distributed in the middle. The push rod 5 is in clearance fit with the strip groove 101 and can slide. The front end of the push rod 5 and the outer side of the inner turntable 7 are provided with flat wire grooves. The inner and outer copper feet of the hairpin flat wire 8 rest against the flat wire grooves of the inner turntable 7 and the push rod 5, respectively.

[0065] The motors used above are servo motors.

[0066] The working principle involves the rotation of the inner and outer motors, which respectively drive the inner turntable 7 and the guide plate 3 to retract the hairpin flat wire 8 towards the center. Meanwhile, the push rod 5 slides within the strip groove 101. The movement of the push rod 5 is propelled by the guide post 6 on the push rod sliding along the curve within the guide groove 301. This part is readily understood by those skilled in the art. This invention primarily describes the design method of the guide groove 301 to address the problems raised in the background art. Two derivation formulas are attached.Figure 4 and 5 As shown in the example diagram below, the formula below can be summarized and entered into an Excel spreadsheet to implement the design of the take-up section of other production lines, improving efficiency and significantly reducing debugging time. (See attached diagram.) Figure 6 and 7 The parameters in the embodiment can be used to generate corresponding curves in the software. The function of the entire structure can be realized through the following process steps. The specific design steps are as follows:

[0067] L1=r*COSα0

[0068] L2 = r * COS(α0 + α)

[0069] L3=L1-L2=r*COSα0-r*COS(α0+α)

[0070] C1 = r * sin(α0 + α)

[0071]

[0072]

[0073]

[0074] The calculation result is:

[0075]

[0076] The formula relating α and S will be used in the following Excel spreadsheet formula for generating guide groove curves.

[0077] The second step involves machining the guide grooves on the guide plate using a machining center, requiring accurate 3D or 2D drawings. Based on the relationships derived in the first step, a Cartesian coordinate system is established in an Excel spreadsheet. The auxiliary parameters used include:

[0078] The total distance from the X-axis to the extended radius of one of the guide disks corresponding to angle M-α;

[0079] The distance from the intersection of the M1 guide groove curve and one of its radii to the X-axis along the radial direction;

[0080] Φ / 2 - Radius of the pitch circle at the starting point of the guide groove;

[0081] x-axis:

[0082] X=(φ / 2-S)*SINα

[0083] M=φ / 2 / COSα

[0084] M1=M-φ / 2+S

[0085] Vertical axis:

[0086] Y=M1*COSα=(M-φ / 2+S)*COSα

[0087] Using the above relationship, insert formulas into an Excel spreadsheet to perform waterfall-style calculations, obtaining multiple coordinate points; the more points, the smoother the result.

[0088] The third step is to use the coordinate system obtained in the second step to generate the guide groove curve in the CAD software to obtain a two-dimensional curve. Then, select the coordinate system in the organized EXCEL table, enter "PL" in the CAD text window, click "space", and then paste the coordinate system by "ctrl+V" in the text window. This will generate the guide groove curve.

[0089] Step 4: Export the 2D curve obtained in step 3 as a DXF file, drag it into 3D software to create a 3D model; import the DXF file into CATIA, copy the imported curve by CTRL+C, create a sketch in the guide plate part, paste it using CTRL+V, then switch to surface design, select the merging command, merge the curves to make them a continuous curve.

[0090] Step 5: Determine the relationship between the inner and outer motor speeds and generate a relationship curve. In step S5, when the guide groove on the guide plate is machined according to the calculated curve, the rotation angle of the inner motor is equal to the rotation angle of the guide plate. Then, the speed relationship between the outer motor ω1 and the inner motor ω2 is: ω1 / ω2 = number of teeth of the driven gear / number of teeth of the driving gear. Then, the pinion and transmission gear can be machined to realize the manufacturing of the part.

[0091] Step 6: Simulation verification and actual manufacturing. The results are verified by simulating the operation with 3D software. Then, the guide plate is manufactured by machining center, and the various parts are assembled to verify the actual effect.

[0092] Although embodiments of this patent have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of this patent. All non-substantial creations made based on these embodiments will be considered as alterations or plagiarism of this patent and shall be protected by law.

Claims

1. A design method for the guide groove of the flat wire motor guide take-up mechanism, wherein the flat wire motor guide take-up mechanism includes a support plate (1), an outer motor (2) is fixed on the lower left side of the support plate (1), a small gear is installed on the head of the outer motor (2), an inner motor (4) is fixed in the middle of the lower end of the support plate (1), an inner turntable (7) is connected to the upper end of the inner motor (4), a guide plate (3) is provided in the middle of the upper end of the support plate (1), guide grooves (301) are evenly distributed on the guide plate (3), and transmission teeth (301) are provided on the outer right side of the guide plate (3). 2) It meshes with a small gear, and a push rod (5) is sandwiched between the support plate (1) and the guide plate (3). A guide post (6) is provided behind the push rod (5), and the guide post (6) is inserted into the guide groove (301). A strip groove (101) is symmetrically distributed in the middle of the support plate (1). The lower part of the push rod (5) is in clearance fit with the strip groove (101) and can slide. Flat wire grooves are provided at the front end of the push rod (5) and the outer side of the inner turntable (7). The inner and outer copper feet of the hairpin flat wire (8) rest against the flat wire grooves of the inner turntable (7) and the push rod (5), respectively. The characteristic is that The design method for the guide groove of the flat wire motor guide take-up mechanism also includes the following steps: S1. Calculate the relationship between the inner motor's change angle α and the push rod displacement S; S2. Since the guide groove on the guide plate is machined by a machining center, an accurate three-dimensional or two-dimensional drawing is required. Based on the relationship obtained in S1, a rectangular coordinate system is established in an Excel spreadsheet. S3. Using the coordinate system obtained in S2, the curve of the guide groove needs to be generated in the CAD software to obtain a two-dimensional curve; S4. Export the two-dimensional curve obtained in S3 as a DXF file and drag it into the three-dimensional software to create a three-dimensional model. S5. Determine the relationship between the inner and outer layer motor speeds and generate a relationship curve. S6, simulation verification and actual manufacturing.

2. The design method of the guide groove for the flat wire motor guide take-up mechanism according to claim 1, characterized in that: The auxiliary parameters required in S1 include: α—Change angle of the inner copper foot; S—Feed distance of the outer copper foot; r—inner diameter of the copper wire; a—span of copper wire; L1—Vertical distance between the initial position of the inner copper foot and the horizontal line direction of the center of the inner turntable (7); L2—the vertical distance between the end point of the inner copper foot and the horizontal line direction of the center of the inner turntable (7); L3—Vertical distance between the initial and final positions of the inner copper foot in the horizontal direction; L4—The vertical distance between the horizontal lines of the end points of the outer copper feet and the inner copper feet. L5—Vertical distance between the initial positions of the outer copper foot and the inner copper foot in the horizontal direction; L6—The vertical distance between the horizontal line direction of the end point of the outer copper foot and the initial point of the inner copper foot; C1—Vertical distance between the end point of the inner copper foot and the vertical center line of the inner turntable (7); C2—Vertical distance between the initial point of the inner copper foot and the vertical center line of the inner turntable (7); α0—Initial point of inner copper foot—Inner layer turntable (7)—End point of inner copper foot, the included angle between the three points, i.e., the initial angle; Perform the following parameter calculations: L1=r*cosα0 L2 = r * cos(α0 + α) L3=L1-L2=r*cosα0-r*cos(α0+α) C1 = r*sin(α0 + α) The calculation result is: The formula relating α and S will be used below when generating guide groove curves.

3. The design method of the guide groove for the flat wire motor guide take-up mechanism according to claim 1, characterized in that: The auxiliary parameters used in S2 include M—the total distance from the extension of one of the radii of the guide disk (3) corresponding to angle α to the X-axis; M1—the distance segment from the intersection of the guide groove curve and one of its radii to the X-axis along the radial direction; Φ / 2—Radius of the starting point pitch circle of the guide groove (301); x-axis: X = (Φ / 2 - S) * sinα M=Φ / 2 / cosα M1=M-Φ / 2+S Vertical axis: Y=M1*cosα=(M-Φ / 2+S)*cosα Using the above relationship, insert formulas into an Excel spreadsheet to perform waterfall-style calculations, obtaining multiple coordinate points; the more points, the smoother the result.

4. The design method of the guide groove for the flat wire motor guide take-up mechanism according to claim 1, characterized in that: S3 selects the coordinate systems in the organized EXCEL table, enters "PL" in the CAD text window, clicks "space", and then pastes the coordinate systems by pressing "ctrl+V" in the text window, which will generate the curve of the guide groove.

5. The design method of the guide groove for the flat wire motor guide take-up mechanism according to claim 1, characterized in that: The S4 process imports the DXF file into CATIA, copies the imported curve using CTRL+C, creates a sketch in the guide disc part, pastes it using CTRL+V, then switches to surface design, selects the merging command, and merges the curves to make them a continuous curve.

6. The design method of the guide groove for the flat wire motor guide take-up mechanism according to claim 1, characterized in that: When the guide groove (301) on the guide disk (3) is machined according to the calculated curve in S5, the rotation angle of the inner motor (4) is equal to the rotation angle of the guide disk (3). Then the speed relationship between the outer motor ω1 and the inner motor ω2 is: ω1 / ω2 = number of teeth of the driven gear / number of teeth of the driving gear. Then the pinion and transmission gear (302) can be machined to realize the manufacturing of the parts.

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