Method for processing and forming flat wire winding, tool and method for using the tool

Abstract

The application provides a processing forming method of a flat wire winding, a tool and a use method of the tool. The processing forming method comprises the following steps: firstly, according to a preset wire insertion rule of the flat wire winding, inserting the flat wire into an insulating part of a wire slot of a stator core to form the flat wire winding; then, performing circumferential torsion on an end part of the flat wire winding; then, performing radial push-torsion on the end part of the flat wire winding after the circumferential torsion, and cutting the end part of the flat wire winding after the radial push-torsion according to a preset straight line segment length of the end part; finally, fixing the cut flat wire winding to perform welding on the end part of the flat wire winding. The processing forming method of the flat wire winding can effectively shorten the height of the end part of the flat wire winding, thereby reducing the volume of the motor, and realizing miniaturization and light weight. When welding the end part of the flat wire winding, the processing tool provided by the application is used to fix the cut flat wire winding, which not only facilitates welding, but also reduces the risk of laser leakage.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and in particular to a method for processing and forming flat wire windings, a tooling, and a method for using the tooling. Background Technology

[0002] With the development of electric vehicle technology, the performance requirements for drive motors are becoming increasingly stringent. As a key component of electric vehicles, the output performance of the drive motor directly affects the efficient operation of the entire machine. Compared to traditional round-wire motors, current flat-wire motors, due to their high copper fill factor achieved through flat-wire windings, improve torque and power density, leading to their increasingly widespread application. Therefore, for flat-wire motors, the processing and shaping of the flat-wire windings determines the motor's performance.

[0003] For motors using flat wire windings, the axial height of the motor's outer envelope depends on the height of the pin wire (straight segment) at the winding end. Therefore, while ensuring motor performance, how to optimize the height of the pin wire at the winding end to reduce the size of the motor stator's outer envelope, thereby reducing the space occupied by the motor and ensuring the insulation distance to ground, has increasingly become one of the technical problems that those skilled in the art urgently need to solve.

[0004] It should be noted that the information disclosed in the background section of this invention is intended only to enhance the understanding of the general background of this invention, and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0005] The purpose of this invention is to optimize the height of the straight section at the end of the flat wire winding to reduce the outer envelope size of the motor stator. This invention provides a method for processing and forming a flat wire winding, a tooling, and a method for using the tooling. This invention can effectively shorten the height of the straight section at the end of the flat wire winding, thereby reducing the space occupied by the motor and ensuring the insulation distance relative to ground, further improving the performance of the motor.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a method for processing and forming flat wire windings, comprising:

[0007] According to the preset insertion rules of the flat wire winding, the flat wire is inserted into the insulation of the wire slot of the stator core to form a flat wire winding.

[0008] The ends of the flat wire winding are circumferentially twisted;

[0009] The ends of the circumferentially twisted flat wire winding are radially twisted, and the ends of the radially twisted flat wire winding are cut according to the preset straight segment length of the ends.

[0010] The cut flat wire winding is fixed in place so that the ends of the flat wire winding are welded.

[0011] Optionally, the step of radially twisting the end of the circumferentially twisted flat wire winding and cutting the end of the radially twisted flat wire winding according to a preset straight segment length includes:

[0012] The circumferentially twisted flat wire winding is fixed so that the straight segment at the end of the flat wire winding is perpendicular to the horizontal plane.

[0013] Push and twist the straight segment at the end of the flat wire winding so that the straight segment at the end of the flat wire winding intersects the horizontal plane at an angle.

[0014] The solder joint position of the flat wire winding is determined according to the preset straight segment length at the end;

[0015] Move the cutting tool to the horizontal plane where the solder joint of the flat wire winding is located to cut off the excess straight segment at the end of the flat wire winding.

[0016] Optionally, fixing the cut flat wire winding to weld the ends of the flat wire winding includes:

[0017] The flat wire winding is fixed such that the welding surface at the end of the flat wire winding is parallel to the horizontal plane;

[0018] The flat wire winding is covered, and the welding surface at the end of the flat wire winding is exposed;

[0019] The welding direction of the welding tool is controlled to be orthogonal to the welding surface of the end of the flat wire winding, and the end of the flat wire winding is welded.

[0020] Optionally, the welding direction of the welding tool is perpendicular to the horizontal plane.

[0021] Optionally, the flat wire includes enameled flat copper wire, and the flat wire winding includes a hair-pin winding and an I-pin winding;

[0022] The step of inserting flat wires into the insulating parts of the stator core slots according to the preset insertion rules of the flat wire winding to form a flat wire winding includes:

[0023] The insulating component is inserted into the slot of the stator core;

[0024] The enameled flat copper wire is pre-treated according to the configuration of the flat wire winding;

[0025] The pre-treated enameled flat copper wire is inserted into the insulating part of the slot inserted into the stator core.

[0026] To achieve the above objectives, the present invention also provides a processing fixture for flat wire windings, the processing fixture comprising: a first fixture, a second fixture, and a third fixture;

[0027] The first tooling includes an arc surface with a plurality of through holes, the arc surface being able to shield the flat wire winding and each of the through holes matching the end of the flat wire winding;

[0028] The second and third tooling are detachably disposed on opposite sides of the arc surface; the convex side of the arc surface of the first tooling, the second tooling, and the third tooling form a groove structure.

[0029] Optionally, the through holes are arranged in an array, and along the extension direction of the groove structure, the distance between two adjacent through holes is equal to the distance between two adjacent ends of the flat wire winding.

[0030] Optionally, it also includes several groove-shaped guide lines, which are arranged in a crisscross pattern on the concave side of the arc surface;

[0031] The through hole is located on the arc surface between adjacent guide patterns.

[0032] Optionally, the machining fixture further includes a barrier disposed around each of the through holes, the barrier being located on the concave side of the arc surface of the first fixture.

[0033] To achieve the above objectives, the present invention also provides a method of using a processing fixture for any of the above-described flat wire windings, the method comprising:

[0034] The flat wire winding is placed on the protruding side of the arc surface of the first tooling and the welding surface of the end of the flat wire winding is aligned with the through hole, so that the first tooling covers the flat wire winding and the welding surface of the end of the flat wire winding is exposed to the concave side of the arc surface of the first tooling through the through hole.

[0035] The second tooling and the third tooling are placed on opposite sides of the first tooling, such that the flat wire winding is located in the groove of the groove structure formed by the second tooling, the first tooling and the third tooling;

[0036] The second and third tooling are controlled to move closer to the flat wire winding to fix the flat wire winding.

[0037] Compared with the prior art, the processing and forming method, tooling, and method of using the tooling provided by the present invention have the following advantages:

[0038] The method for forming a flat wire winding provided by this invention first involves inserting a flat wire into the insulating part of the stator core slot according to a preset insertion rule to form a flat wire winding; then, the end of the flat wire winding is circumferentially twisted; next, the end of the circumferentially twisted flat wire winding is radially pushed and twisted, and the end of the radially pushed and twisted flat wire winding is cut according to a preset straight segment length; finally, the cut flat wire winding is fixed, and the end of the flat wire winding is welded. Therefore, the method for forming a flat wire winding provided by this invention, by radially pushing and twisting the end of the circumferentially twisted flat wire winding, creates a certain angle between the welding surface of the end of the flat wire winding and the pin of the end of the flat wire winding, making it easier to cut the end of the radially pushed and twisted flat wire winding according to the preset straight segment length. Furthermore, by cutting the ends of the radially twisted flat wire winding, the height of the ends of the flat wire winding is effectively shortened, thereby reducing the space occupied by the motor and ensuring the insulation distance relative to the ground, thus further reducing the size of the motor and achieving miniaturization and weight reduction. When welding the ends of the flat wire winding, fixing the cut flat wire winding not only facilitates welding but also reduces the risk of laser leakage.

[0039] The processing fixture for flat wire windings provided by this invention includes: a first fixture, a second fixture, and a third fixture; the first fixture includes an arc surface with a plurality of through holes, the arc surface being able to shield the flat wire winding, and each of the through holes matching the end of the flat wire winding; the second fixture and the third fixture are detachably disposed on opposite sides of the arc surface; the protruding side of the arc surface of the first fixture, the second fixture, and the third fixture form a groove structure. Therefore, the processing fixture for flat wire windings provided by this invention can be used to fix the cut flat wire winding. The arc surface structure of the first fixture is more conducive to making the welding surface of the end of the flat wire winding orthogonal to the welding direction of the welding tool, making it easier to weld the end of the flat wire winding; moreover, the arc surface has a plurality of through holes matching the end of the flat wire winding, which facilitates welding, effectively reduces the risk of laser leakage, and better protects the flat wire winding. Furthermore, the protruding side of the arc surface of the first fixture, the second fixture, and the third fixture form a groove structure, which further facilitates fixing the flat wire winding. Furthermore, the second and third tooling are detachably connected to the first tooling, thus the processing tooling for flat wire windings provided by the present invention is not only easy to use, but also easy to store.

[0040] The method of using the processing fixture provided by this invention simply involves placing the flat wire winding on the convex side of the arc surface of the first fixture and aligning the welding surface of the end of the flat wire winding with the through hole, so that the first fixture covers the flat wire winding and the welding surface of the end of the flat wire winding is exposed through the through hole to the concave side of the arc surface of the first fixture; then, the second fixture and the third fixture are placed on opposite sides of the first fixture, so that the flat wire winding is located in the groove of the groove structure formed by the second fixture, the first fixture, and the third fixture; then, the second fixture and the third fixture are controlled to move closer to the flat wire winding to fix the flat wire winding. Therefore, the method of using the processing fixture is clear, straightforward, and easy to implement. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the overall process of the flat wire winding forming method provided in Embodiment 1 of the present invention;

[0042] Figure 2 This is a structural diagram of the end of a flat wire winding in the prior art;

[0043] Figure 3 A schematic diagram of the structure of the end of the flat wire winding after push-twist and cutting obtained by applying Embodiment 1 of the present invention;

[0044] Figure 4 This is a schematic diagram illustrating the positional relationship between the cutting tool and the flat wire winding during cutting, as shown in Embodiment 1 of the present invention.

[0045] Figure 5 This is a schematic diagram showing the positional relationship between the fixing fixture and the flat wire winding during welding in Embodiment 1 of the present invention;

[0046] Figure 6 This is a schematic diagram of the processing fixture for the flat wire winding provided in Embodiment 2 of the present invention;

[0047] Figure 7 This is a schematic diagram of the processing tooling for the flat wire winding according to Embodiment 3 of the present invention.

[0048] Figure 8 This is a schematic diagram of the overall process for using the processing fixture for the flat wire winding provided in Embodiment 3 of the present invention.

[0049] The accompanying figure is labeled as follows:

[0050] Flat wire winding - 100, solder joint positions - 110a, 110b, cutting tool - 200;

[0051] First tooling - 310, curved surface - 311, through hole - 312, guide texture - 313, enclosure - 314, second tooling - 320, third tooling - 330. Detailed Implementation

[0052] The following detailed description, in conjunction with the accompanying drawings, provides a further detailed explanation of the processing and forming method, tooling, and usage method of the flat wire winding proposed in this invention. The advantages and features of this invention will become clearer from the following description. It should be noted that the drawings are in a very simplified form and use non-precise proportions, intended only to facilitate and clearly illustrate the embodiments of this invention. Please refer to the drawings to make the objectives, features, and advantages of this invention more apparent and understandable. It should be understood that the structures, proportions, sizes, etc., depicted in the accompanying drawings are only for illustrative purposes and to enable those skilled in the art to understand and read them, and are not intended to limit the implementation conditions of this invention. Any modifications to the structure, changes in proportions, or adjustments to the size, provided they produce the same or similar effects and achieve the same objectives as this invention, should still fall within the scope of the technical content disclosed in this invention. Specific design features of this invention disclosed herein, including, for example, specific dimensions, orientations, positions, and shapes, will be determined in part by the specific application and usage environment. Furthermore, in the embodiments described below, the same reference numerals are sometimes used across different drawings to denote the same parts or parts with the same function, omitting repeated descriptions. In this specification, similar reference numerals and letters are used to denote similar items; therefore, once an item is defined in one figure, it need not be discussed further in subsequent figures. Furthermore, if the methods described herein involve a series of steps, and the order of these steps presented herein is not necessarily the only possible order in which they can be performed, some of the described steps may be omitted and / or other steps not described herein may be added to the method.

[0053] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element. The singular forms “a,” “an,” and “the” include plural objects. The term “or” is generally used to mean “and / or,” the term “several” is generally used to mean “at least one,” and the term “at least two” is generally used to mean “two or more.” Furthermore, the terms “first,” “second,” and “third” are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated.

[0054] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0055] In the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0056] Example 1

[0057] This embodiment provides a method for processing and forming a flat wire winding 100. For details, please refer to... Figure 1It schematically illustrates the overall process flow diagram of the processing and forming method of the flat wire winding 100 provided in this embodiment. From Figure 1 As can be seen, the processing and forming method of the flat wire winding 100 provided in this embodiment includes the following steps:

[0058] S100: According to the preset insertion rules of the flat wire winding 100, the flat wire is inserted into the insulation of the wire slot of the stator core to form the flat wire winding 100.

[0059] S200: The ends of the flat wire winding 100 are circumferentially twisted;

[0060] S300: Radially push and twist the end of the circumferentially twisted flat wire winding 100, and cut the end of the radially twisted flat wire winding 100 according to the preset straight segment length of the end.

[0061] S400: Fix the cut flat wire winding 100 to weld the ends of the flat wire winding 100.

[0062] Therefore, the processing and forming method of the flat wire winding 100 provided in this embodiment, by radially twisting the end of the circumferentially twisted flat wire winding 100, creates a certain angle between the welding surface of the end of the flat wire winding 100 and the pin of the end of the flat wire winding 100. This facilitates cutting the end of the radially twisted flat wire winding 100 according to the preset straight segment length. Furthermore, cutting the end of the radially twisted flat wire winding 100 effectively shortens the height of the end of the flat wire winding 100, thereby reducing the space occupied by the motor and ensuring the insulation distance relative to the ground. This further reduces the size of the motor, laying a good foundation for achieving motor miniaturization and weight reduction. When welding the end of the flat wire winding 100, fixing the cut flat wire winding 100 not only facilitates welding but also reduces the risk of laser leakage.

[0063] Specifically, please see Figure 2 and Figure 3 ,in, Figure 2 This is a structural diagram of the end of the flat wire winding 100 in the prior art; Figure 3 This is a schematic diagram of the structure of the flat wire winding 100 after push-twist and cutting, obtained using Embodiment 1 of the present invention. (Comparison) Figure 2 and Figure 3It is not difficult to see that, using the processing and forming method of the flat wire winding 100 provided in this embodiment, the length of the straight segment at the end of the flat wire winding 100 after twisting and cutting is significantly shortened compared to the solder joint position 110b of the flat wire winding 100 in the prior art. This further reduces the size of the motor, laying a good foundation for achieving motor miniaturization and weight reduction.

[0064] It should be specifically noted that, as those skilled in the art will understand, the present invention does not impose any limitations on the specific material and configuration of the flat wire winding 100. As one preferred embodiment, the flat wire comprises enameled flat copper wire. Further, the configuration of the flat wire winding 100 includes, but is not limited to, hair-pin windings and I-pin windings.

[0065] In one preferred embodiment, step S100, which involves inserting the flat wire into the insulating member of the stator core slot according to a preset insertion rule of the flat wire winding 100 to form the flat wire winding 100, includes:

[0066] S110: The insulating component is inserted into the slot of the stator core;

[0067] S120: Pre-process the enameled flat copper wire according to the configuration of the flat wire winding 100;

[0068] S130: Insert the pre-treated enameled flat copper wire into the insulating part of the slot inserted into the stator core.

[0069] Specifically, the insulating component includes insulating paper. The pretreatment of the enameled flat copper wire includes wire shaping (e.g., bending into a hairpin shape, I-shape, etc.) according to the configuration of the flat wire winding 100 (e.g., hair-PIN winding or I-PIN winding, the preset insertion rule of the flat wire winding 100 is determined by the configuration of the edge winding).

[0070] In one preferred embodiment, step S300, which involves radially twisting the end of the circumferentially twisted flat wire winding 100 and cutting the end of the radially twisted flat wire winding 100 according to a preset straight segment length, includes:

[0071] S310: Fix the circumferentially twisted flat wire winding 100 so that the straight segment at the end of the flat wire winding 100 is perpendicular to the horizontal plane.

[0072] S320: Push and twist the straight segment at the end of the flat wire winding 100 so that the straight segment at the end of the flat wire winding 100 is oblique to the horizontal plane.

[0073] S330: Determine the solder joint position of the flat wire winding 100 according to the preset straight segment length at the end;

[0074] S340: Move the cutting tool 200 to the horizontal plane where the solder joint of the flat wire winding 100 is located, and cut off the excess straight segment at the end of the flat wire winding 100.

[0075] The processing and forming method of the flat wire winding 100 provided in this embodiment, by making the straight segment of the end of the flat wire winding 100 perpendicular to the horizontal plane, not only facilitates the fixing of the flat wire winding 100 during cutting, but also facilitates the cutting tool 200 to move in the horizontal direction, improving cutting efficiency. Furthermore, by pushing and twisting the straight segment of the end of the flat wire winding 100, the straight segment of the end of the flat wire winding 100 is made oblique to the horizontal plane. This makes it easier to control the welding surface (i.e., the plane where the welding point is located) of the end of the flat wire winding 100 after cutting to be parallel to the horizontal plane, thereby making the tilt angle of the end of the flat wire winding (i.e., the extension direction of the gap between the two pin wires of the flat wire winding) more conducive to the protection and welding of the flat wire winding 100 during welding.

[0076] It should be noted that, as those skilled in the art will understand, the present invention does not limit the specific value of the length of the end straight segment described in step S330. In practical applications, it should be selected according to actual needs. However, it is understood that if the length of the straight segment at the end of the flat wire winding 100 is longer, it is more conducive to subsequent welding, but the height reduction of the axial end of the flat wire winding 100 is limited, which is not conducive to product size optimization; conversely, if the length of the straight segment at the end of the flat wire winding 100 is shorter (even to 0), the height of the axial end of the flat wire winding 100 is smaller, which is more conducive to product size optimization, but during welding, it may rely more on the processing tooling provided in Embodiment 2 below.

[0077] Obviously, the present invention does not impose any limitations on the cutting tool 200. Specifically, please refer to... Figure 4 It schematically illustrates the positional diagram between the cutting tool 200 and the flat wire winding 100 during cutting using Embodiment 1 of the present invention. From Figure 4 As can be seen, the cutting tool 200 is a flat blade. In other embodiments, the cutting tool 200 may also be a guillotine cutter, a hydraulic cutter, etc.

[0078] In one preferred embodiment, step S340, fixing the cut flat wire winding 100 to weld the ends of the flat wire winding 100, includes:

[0079] S341: Fix the flat wire winding 100 such that the welding surface at the end of the flat wire winding 100 is parallel to the horizontal plane;

[0080] S342: Cover the flat wire winding 100 and expose the welding surface at the end of the flat wire winding 100;

[0081] S343: Control the welding direction of the welding tool to be orthogonal to the welding surface of the end of the flat wire winding 100, and weld the end of the flat wire winding 100.

[0082] Specifically, please refer to Figure 5, which schematically illustrates the positional relationship between the fixing fixture and the flat wire winding 100 during welding in this embodiment. It can be seen that the processing and forming method of the flat wire winding 100 provided in this embodiment involves fixing the flat wire winding 100 so that the welding surface at the end of the flat wire winding 100 is parallel to the horizontal plane; then, the flat wire winding 100 is shielded, exposing the welding surface at the end of the flat wire winding 100; finally, the welding direction of the welding tool is controlled to be orthogonal to the welding surface at the end of the flat wire winding 100, and the end of the flat wire winding 100 is welded. Thus, the welding surface at the end of the flat wire winding 100 is parallel to the horizontal plane (at this time, the gap between the two pin wires at the end of the twisted flat wire winding has an angle with the horizontal plane), which not only facilitates welding but also reduces the risk of laser leakage by shielding the flat wire winding 100, better protecting the enamel film of the flat wire winding. This improves the forming quality of the flat wire winding 100.

[0083] It should be specifically noted that, as those skilled in the art will understand, Figure 5 The machining fixtures shown for use during welding are merely a description of a preferred embodiment and not a limitation of the invention. In other embodiments, other machining fixtures may be used to shield and fix the flat wire winding 100.

[0084] In one preferred embodiment, the welding direction of the welding tool is perpendicular to the horizontal plane. This allows for an angle between the welding direction of the welding tool and the welding surface at the end of the flat wire winding 100, making it easier to observe the specific welding process at the welding point, thereby improving welding efficiency and quality.

[0085] Therefore, the processing and forming method of the flat wire winding 100 provided in this embodiment can maintain the spacing at the ends of the flat wire winding 100 by twisting the ends of the flat wire winding 100 to different degrees and arranging them to a suitable wire spacing before welding and fixing them, thereby improving the performance of the motor.

[0086] Additionally, please continue to see Figure 1After welding the ends of the flat wire winding 100, the method further includes:

[0087] S500: Perform subsequent processing on the welded flat wire winding 100.

[0088] More specifically, the subsequent processes include, but are not limited to, impregnation and painting of the ends of the flat wire winding 100, and overall defect detection. For details, please refer to the relevant descriptions in the prior art. They will not be elaborated here.

[0089] In summary, compared with the prior art, the processing and forming method of the flat wire winding 100 provided in this embodiment, through minor modifications to the existing production line (adding steps S300 and S400), not only effectively shortens the height of the end of the flat wire winding 100, thereby reducing the space occupied by the motor and ensuring the insulation distance relative to ground, but also further reduces the size of the motor, achieving miniaturization and weight reduction. Moreover, the modifications to the existing product line are minimal, and the main part of the existing production line can be used, achieving the production of the new type of flat wire winding 100 (with a significant reduction in the straight section of the end of the flat wire winding 100) with minimal production line iteration investment cost.

[0090] Example 2

[0091] This embodiment provides a machining fixture for a flat wire winding 100. For details, please refer to [link to relevant documentation]. Figure 6 The diagram illustrates the structure of the machining fixture for the flat wire winding 100 provided in Embodiment 2 of the present invention. Figure 6 As can be seen, the machining fixtures provided in this embodiment include: a first fixture 310, a second fixture 320, and a third fixture 330.

[0092] Specifically, the first tooling 310 includes an arc surface 311 with a plurality of through holes 312. The arc surface 311 can cover the flat wire winding 100, and each of the through holes 312 matches the end of the flat wire winding 100. The second tooling 320 and the third tooling 330 are detachably disposed on opposite sides of the arc surface 311; the convex side of the arc surface 311 of the first tooling 310 (below the arc surface 311 in the illustrated direction), the second tooling 320, and the third tooling 330 form a groove structure (not shown in the figure).

[0093] Therefore, the processing fixture for the flat wire winding 100 provided in this embodiment can be used to fix the cut flat wire winding 100. The arc surface 311 structure of the first fixture 310 is more conducive to making the welding surface of the end of the flat wire winding 100 orthogonal to the welding direction of the welding tool, which is more convenient for welding the end of the flat wire winding 100. Moreover, the arc surface 311 has several through holes 312 that match the end of the flat wire winding 100, which not only facilitates welding and effectively reduces the risk of laser leakage, but also better protects the flat wire winding 100. Furthermore, the protruding side of the arc surface 311 of the first fixture 310, the second fixture 320, and the third fixture 330 form a groove structure, which is more convenient for fixing the flat wire winding 100. Furthermore, the second fixture 320 and the third fixture 330 are detachably connected to the first fixture 310. Thus, the processing fixture for the flat wire winding 100 provided by the present invention is not only easy to use, but also easy to store.

[0094] Please continue reading Figure 6 In one preferred embodiment, the through holes 312 are arranged in an array, and along the extension direction of the groove structure, the distance between two adjacent through holes 312 is equal to the distance between two adjacent ends of the flat wire winding 100.

[0095] The machining fixture for the flat wire winding 100 provided in this embodiment has through holes 312 arranged in an array, which facilitates the manufacturing of the machining fixture. Furthermore, along the extending direction of the groove structure, the distance between two adjacent through holes 312 is equal to the distance between two adjacent ends of the flat wire winding 100, which further facilitates the fixing of the flat wire winding 100 and the alignment of the ends of the flat wire winding 100 with the through holes 312.

[0096] In one exemplary embodiment, the first machining fixture further includes a plurality of groove-shaped guide lines 313, which are arranged in a crisscross pattern on the concave side of the arc surface 311 (below the arc surface 311 in the illustrated direction); the through hole 312 is located on the arc surface 311 between adjacent guide lines 313.

[0097] The processing fixture for the flat wire winding 100 provided in this embodiment further includes a plurality of groove-shaped guide lines 313, which are arranged crisscrossingly on the concave side of the arc surface 311 (below the arc surface 311 in the illustrated direction); the through hole 312 is located on the arc surface 311 between adjacent guide lines 313. This facilitates the guiding and fixing of the flat wire winding 100.

[0098] In one exemplary embodiment, the machining fixture further includes a retaining wall 314 disposed around each of the through holes 312, the retaining wall 314 being located on the concave side of the arc surface 311 of the first fixture 310. Thus, the machining fixture for the flat wire winding 100 provided in this embodiment, by providing a retaining wall 314 around each of the through holes 312, can further reduce the risk of laser leakage, thereby improving the quality of the flat wire winding 100.

[0099] It should be noted that, as those skilled in the art will understand, although the processing fixture for the flat wire winding 100 provided in the embodiment is detachably connected to the first fixture 310 via the second fixture 320 and the third fixture 330, in other embodiments, the first fixture 310 may also be integrally formed with one of the second fixture 320 and the third fixture 330, and the present invention does not limit this.

[0100] For details on the use of the processing fixture for the flat wire winding 100 provided in this embodiment, please refer to the detailed description of Embodiment 3 below, which will not be elaborated here.

[0101] Example 3

[0102] Corresponding to Embodiment 2, this embodiment provides a method for using a machining fixture for the flat wire winding 100. For details, please refer to [link to previous document]. Figure 5 , Figure 7 and Figure 8 , Figure 5 This is a schematic diagram showing the positional relationship between the fixing fixture and the flat wire winding during welding in Embodiment 1 of the present invention. Figure 7 This is a schematic diagram illustrating the process of using the machining fixture for the flat wire winding according to Embodiment 3 of the present invention. Figure 8 A schematic diagram illustrating the overall process of using the machining fixture for the flat wire winding 100 provided in this embodiment is given. From Figure 8 As can be seen, the method of use includes:

[0103] Step A: Place the flat wire winding 100 on the protruding side of the arc surface 311 of the first tooling 310 and align the welding surface of the end of the flat wire winding 100 with the through hole 312, so that the first tooling 310 covers the flat wire winding 100 and the welding surface of the end of the flat wire winding 100 is exposed to the concave side of the arc surface 311 of the first tooling 310 through the through hole 312;

[0104] Step B: Place the second tooling 320 and the third tooling 330 on opposite sides of the first tooling 310, so that the flat wire winding 100 is located in the groove of the groove structure formed by the second tooling 320, the first tooling 310 and the third tooling 330;

[0105] Step C: Control the second tooling 320 and the third tooling 330 to move closer to the flat wire winding 100 to fix the flat wire winding 100.

[0106] With this configuration, the method of using the processing fixture provided in this embodiment only requires placing the flat wire winding 100 on the protruding side of the arc surface 311 of the first fixture 310 and aligning the welding surface of the end of the flat wire winding 100 with the through hole 312, so that the first fixture 310 covers the flat wire winding 100 and the welding surface of the end of the flat wire winding 100 is exposed through the through hole 312 to the concave side of the arc surface 311 of the first fixture 310; then, the second fixture 320 and the third fixture 330 are placed on opposite sides of the first fixture 310, so that the flat wire winding 100 is located in the groove of the groove structure formed by the second fixture 320, the first fixture 310, and the third fixture 330; finally, the second fixture 320 and the third fixture 330 are controlled to move closer to the flat wire winding 100 to fix the flat wire winding 100. Therefore, the method of using the processing fixture provided in this embodiment is clear, straightforward, and easy to implement.

[0107] In summary, compared with the prior art, the processing and forming method, tooling, and method of using the tooling provided by the present invention for the flat wire winding 100 have the following advantages:

[0108] 1. The processing and forming method of the flat wire winding 100 provided by the present invention involves radially twisting the end of the circumferentially twisted flat wire winding 100, so that there is a certain angle between the welding surface of the end of the flat wire winding 100 and the pin of the end of the flat wire winding 100. This makes it easier to cut the end of the radially twisted flat wire winding 100 according to the preset straight segment length of the end. Furthermore, by cutting the end of the radially twisted flat wire winding 100, the height of the end of the flat wire winding 100 is effectively shortened, thereby reducing the space occupied by the motor and ensuring the insulation distance relative to the ground, thereby further reducing the size of the motor and achieving miniaturization and weight reduction. When welding the end of the flat wire winding 100, fixing the cut flat wire winding 100 not only facilitates welding but also reduces the risk of laser leakage.

[0109] 2. The processing fixture for the flat wire winding 100 provided by the present invention can be used to fix the cut flat wire winding 100. The arc surface 311 structure of the first fixture 310 is more conducive to making the welding surface of the end of the flat wire winding 100 orthogonal to the welding direction of the welding tool, which is more convenient for welding the end of the flat wire winding 100. Moreover, the arc surface 311 has a plurality of through holes 312 that match the end of the flat wire winding 100, which can better protect the flat wire winding 100 while facilitating welding and effectively reducing the risk of laser leakage. Further, the protruding side of the arc surface 311 of the first fixture 310, the second fixture 320 and the third fixture 330 form a groove structure, which is more convenient for fixing the flat wire winding 100. Furthermore, the second fixture 320 and the third fixture 330 are detachably connected to the first fixture 310. Thus, the processing fixture for the flat wire winding 100 provided by the present invention is not only easy to use, but also easy to store.

[0110] 3. The method of using the processing tooling provided by this invention is clear and easy to implement.

[0111] It should be noted that the apparatus and methods disclosed in the embodiments herein can also be implemented in other ways. The apparatus embodiments described above are merely illustrative; for example, the flowcharts and block diagrams in the accompanying drawings show the architecture, functionality, and operation of possible implementations of apparatus, methods, and computer program products according to various embodiments herein. In this regard, each block in a flowchart or block diagram may represent a module, program, or part of code containing one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions marked in the blocks may occur in a different order than those marked in the drawings. For example, two consecutive blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It should also be noted that each block in a block diagram and / or flowchart, and combinations of blocks in block diagrams and / or flowcharts, can be implemented using a dedicated hardware-based system to perform the specified function or action, or can be implemented using a combination of dedicated hardware and computer instructions.

[0112] In addition, the functional modules in the various embodiments of this article can be integrated together to form an independent part, or each module can exist independently, or two or more modules can be integrated to form an independent part.

[0113] The above description is merely a description of preferred embodiments of the present invention and is not intended to limit the scope of the invention in any way. Any changes or modifications made by those skilled in the art based on the above disclosure are within the protection scope of the present invention. Obviously, those skilled in the art can make various modifications and variations to the present invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the present invention and its equivalents, the present invention also intends to include these modifications and variations.

Claims

1. A method for processing and forming a flat wire winding, characterized in that, include: According to the preset insertion rules of the flat wire winding, the flat wire is inserted into the insulation of the wire slot of the stator core to form a flat wire winding. The ends of the flat wire winding are circumferentially twisted; The ends of the circumferentially twisted flat wire winding are radially twisted, and the ends of the radially twisted flat wire winding are cut according to the preset straight segment length of the ends. The flat wire winding is fixed such that the welding surface at the end of the flat wire winding is parallel to the horizontal plane; The flat wire winding is covered, and the welding surface at the end of the flat wire winding is exposed; The welding direction of the welding tool is controlled to be orthogonal to the welding surface of the end of the flat wire winding, and the end of the flat wire winding is welded.

2. The processing and forming method according to claim 1, characterized in that, The step of radially twisting the end of the circumferentially twisted flat wire winding and cutting the end of the radially twisted flat wire winding according to the preset straight segment length of the end includes: The circumferentially twisted flat wire winding is fixed so that the straight segment at the end of the flat wire winding is perpendicular to the horizontal plane. Push and twist the straight segment at the end of the flat wire winding so that the straight segment at the end of the flat wire winding intersects the horizontal plane at an angle. The solder joint position of the flat wire winding is determined according to the preset straight segment length at the end; Move the cutting tool to the horizontal plane where the solder joint of the flat wire winding is located to cut off the excess straight segment at the end of the flat wire winding.

3. The processing and forming method according to claim 1, characterized in that, The welding direction of the welding tool is perpendicular to the horizontal plane.

4. The processing and forming method according to any one of claims 1-3, characterized in that, The flat wire includes enameled flat copper wire, and the flat wire winding includes a hair-pin winding and an I-pin winding; The step of inserting flat wires into the insulating parts of the stator core slots according to the preset insertion rules of the flat wire winding to form a flat wire winding includes: The insulating component is inserted into the slot of the stator core; The enameled flat copper wire is pre-treated according to the configuration of the flat wire winding; The pre-treated enameled flat copper wire is inserted into the insulating part of the slot inserted into the stator core.

5. A machining fixture for flat wire windings, characterized in that, The processing and forming method according to any one of claims 1-4, wherein the processing fixture includes: a first fixture, a second fixture, and a third fixture; The first tooling includes an arc surface with a plurality of through holes, the arc surface being able to shield the flat wire winding and each of the through holes matching the end of the flat wire winding; The second and third tooling are detachably disposed on opposite sides of the arc surface; the convex side of the arc surface of the first tooling, the second tooling, and the third tooling form a groove structure.

6. The machining tooling according to claim 5, characterized in that, The through holes are arranged in an array, and along the extension direction of the groove structure, the distance between two adjacent through holes is equal to the distance between two adjacent ends of the flat wire winding.

7. The machining tooling according to claim 5, characterized in that, It also includes several groove-shaped guide lines, which are arranged in a crisscross pattern on the concave side of the arc surface; The through hole is located on the arc surface between adjacent guide patterns.

8. The machining tooling according to claim 5, characterized in that, It also includes a barrier disposed around each of the through holes, the barrier being located on the concave side of the arc surface of the first tooling.

9. A method of using a machining fixture for flat wire windings as described in any one of claims 5-8, characterized in that, include: The flat wire winding is placed on the protruding side of the arc surface of the first tooling and the welding surface of the end of the flat wire winding is aligned with the through hole, so that the first tooling covers the flat wire winding and the welding surface of the end of the flat wire winding is exposed to the concave side of the arc surface of the first tooling through the through hole. The second tooling and the third tooling are placed on opposite sides of the first tooling, such that the flat wire winding is located in the groove of the groove structure formed by the second tooling, the first tooling and the third tooling; The second and third tooling are controlled to move closer to the flat wire winding to fix the flat wire winding.

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