Forming method and wire arranging tool for distributed wave winding

Abstract

This invention relates to the fabrication of motor windings, specifically providing a method for forming distributed waveform windings and a wiring fixture, aiming to solve the problems of easy damage to the insulating varnish film at the winding ends, large space occupation at the winding ends, and inflexible wiring in existing technologies. To this end, the winding forming method of this invention includes: S1: Folding the winding wire to create a first connecting segment and placing it on the wiring fixture; S2: Locating the first top bending point, rotating the winding wire behind this point around the center point to fold out the first end; S3: Folding out the second end and the second connecting segment; S4: Rotating the portion behind the first top bending point in the opposite direction to the rotation direction in S2, flattening the second connecting segment onto the wiring fixture; S5: Repeating S2-S4 to fold out several winding ends and connecting segments, completing the forming of a single winding wire. This invention reduces the twisting at the winding ends, minimizes damage to the insulating varnish film, and optimizes the layout, resulting in a smaller winding space and more flexible wiring.

Description

Technical Field

[0001] This invention relates to the field of motor winding manufacturing, specifically providing a method for forming distributed waveform windings and a wiring fixture. Background Technology

[0002] Flat-wire motors replace the original round wires with flat wires. With the same space requirements, flat wires can improve slot fill factor, reduce space waste, and increase power density compared to round wires, thus their use is becoming increasingly widespread. Distributed windings offer better performance than centralized windings. Distributed windings consist of n continuous, wavy, intertwined winding wires, each with a start and end point, as well as connecting sections and herringbone-shaped winding ends.

[0003] Existing flat wire winding technology presents several problems during forming. For example, the winding wire undergoes multiple forward and reverse twists to form the winding ends, which can easily damage the insulating varnish film on the winding wire, leading to insulation failure. Other winding forming methods employ a method of nesting small-wave winding metal wires within large-wave winding metal wires, causing the winding ends to occupy more space vertically. Furthermore, these winding wires often use a same-layer design, with the winding wires exiting and returning to the first layer, requiring them to avoid each other, further increasing the space occupied at the winding ends. Simultaneously, the large-wave-within-a-small-wave method limits its applicability to certain types of motors; for example, it works for 48-slot motors but not 54-slot motors. Moreover, in existing technologies, several winding wires are processed and formed simultaneously, resulting in a fixed span for the entire winding. If the span needs to be changed, the entire processing method becomes unsuitable, preventing flexible adjustment of the winding routing according to actual conditions.

[0004] Accordingly, there is a need in the field for a new winding forming method to solve the above problems. Summary of the Invention

[0005] The present invention aims to solve or alleviate at least some of the above-mentioned technical problems, namely, to solve or alleviate one or more of the problems in the prior art, such as easy damage to the insulating varnish film at the winding end, large space occupation at the winding end, and inflexible winding routing. To this end, in one aspect, the present invention provides a method for forming a distributed waveform winding, the method utilizing a wiring fixture having multiple wire-laying slots arranged on both sides to form a first layer of winding slots and a second layer of winding slots. The method includes the following steps: S1: Folding out a first connecting segment of the winding wire and then placing it into one of the wire-laying slots in the first layer of winding slots of the wiring fixture; or, first placing the winding wire into one of the wire-laying slots in the first layer of winding slots of the wiring fixture, and then folding out the first connecting segment; S2: Finding a first top bending point, rotating the winding wire behind the first top bending point around the first top bending point as the center point, and folding out a first end; S3: Folding out a second end and a second connecting segment; S4: Rotating the portion behind the first top bending point in the opposite direction according to the rotation direction in S2, thereby flattening the second connecting segment into one of the wire-laying slots in the second layer of winding slots of the wiring fixture; S5: Repeating S2-S4 to fold out several winding ends and connecting segments, completing the forming of a single winding wire.

[0006] In a specific embodiment of the above-mentioned method for forming distributed waveform windings, the length direction of the wiring fixture is the X-axis direction, the width direction is the Y-axis direction, and the height direction is the Z-axis direction. Steps S1-S5 are as follows: S1: Fold the winding wire out of the first connecting segment, dividing the entire winding wire into the starting end, the first connecting segment, and the remaining winding wire. Place the first connecting segment in a wire release slot in the first layer of winding slots. S2: Locate the first top bend point. Rotate the winding wire behind the first top bend point around the first top bend point in the Z-axis direction by a certain angle, folding out the first end. At this time, the winding wire behind the first end is located on one side of the second layer of winding slots. S3: Among the winding wires behind the first top bend point, locate the first intermediate bend point and the second intermediate bend point, respectively, and fold them around the X-axis, along the direction closer to and farther from the second layer. S4: Rotate the second end, the second connecting segment, and the remaining winding wire around the first top bend point in the opposite direction of step S2, thereby pressing the second connecting segment into a wire release slot in the second layer of winding grooves; S5: Repeat S2-S4, that is, find the second top bend point, rotate the remaining winding wire behind the second top bend point around the Z-axis in the opposite direction of step S2, thereby pressing the second connecting segment into a wire release slot in the second layer of winding grooves; S6: Repeat S2-S4, that is, find the second top bend point, rotate the remaining winding wire behind the second top bend point around the Z-axis in the opposite direction of step S2, and fold out the third end. At this time, the remaining winding wire behind the second top bend point is located on one side of the first layer of winding grooves; then fold out the fourth end and the third connecting segment in sequence, and then rotate in the opposite direction of the Z-axis to press the third connecting segment into a wire release slot in the first layer of winding grooves; repeat S2-S5 a certain number of times to complete the forming of a single winding.

[0007] In a specific embodiment of the above-mentioned method for forming distributed waveform windings, the method further includes the following steps: S6: Repeat S1 with the second winding wire to fold out the first connecting segment, and then offset the first connecting segment of the second winding wire by n slots and place it into one of the wire release slots in the first layer of winding slots. Then repeat SS to complete the forming of the second winding wire; S7: Repeat S6 a specific number of times to complete the forming of all winding wires; S8: Remove the wiring fixture.

[0008] In a specific embodiment of the above-described method for forming distributed waveform windings, the angle between the first connecting segment and the first end is equal to the angle between the second connecting segment and the second end, the angle between the second connecting segment and the third end, and the angle between the third connecting segment and the fourth end; and / or, the lengths of the first connecting segment, the second connecting segment, and the third connecting segment are equal.

[0009] In a specific embodiment of the above-mentioned method for forming distributed waveform windings, step S3 further includes the following steps: S31: Rotate the winding wire after the first top bend point downward around the X-axis with the first top bend point as the center, and further rotate the winding wire after the first intermediate bend point downward around the X-axis to fold out the second end; S32: Rotate the remaining winding wire upward around the X-axis at the second intermediate bend point to fold out the second connecting segment.

[0010] In a specific embodiment of the above-mentioned method for forming distributed waveform windings, the first connecting segment, the second connecting segment, and the third connecting segment are parallel to the Z-axis direction.

[0011] In a specific embodiment of the above-mentioned method for forming distributed waveform windings, the winding wire is a flat wire with a front side and a side side. In the method, the side side is bent to form the first connecting segment, the second connecting segment and the third connecting segment, and the front side is used to be placed in the wire feeding groove.

[0012] In a specific embodiment of the above-described method for forming distributed waveform windings, the distance between the first end and the second end along the Y-axis is greater than the thickness between the first layer of winding grooves and the second layer of winding grooves.

[0013] On the other hand, the present invention also provides a wiring fixture for manufacturing waveform windings, wherein multiple wire feeding slots of the same size are provided on both sides of the wiring fixture, the wire feeding slots being used to accommodate the intermediate connecting section of the winding wire during the manufacturing of the waveform windings.

[0014] In the specific embodiment of the above-mentioned wiring fixture for making waveform windings, the wire feeding grooves are distributed on both sides of the plate-shaped body, thereby forming a first layer of winding grooves and a second layer of winding grooves. The first layer of winding grooves and the second layer of winding grooves are respectively used to accommodate two adjacent intermediate connecting sections in each winding wire.

[0015] By employing the above technical solution, the winding forming method of the present invention can reduce the twisting and turning of the winding wire ends, thereby reducing damage to the insulating varnish film. Simultaneously, the wiring fixture of the present invention uses a two-layer winding slot design, keeping the winding wires parallel to each other without a nested design. This avoids the space occupied by two winding wires nested together. Furthermore, the two-layer design allows the winding wire to enter the second layer without needing to avoid obstacles, further reducing the space occupied at the winding ends. The method of sequentially folding out the connecting section and winding ends in this solution allows for easy adjustment of the span, enabling the design of different spans, winding wire numbers, and other parameters according to different motors, thus maximizing the motor's efficiency. Attached Figure Description

[0016] The preferred embodiments of the present invention are described below with reference to the accompanying drawings, in which:

[0017] Figure 1 This is a schematic diagram of a portion of the winding wire from a certain perspective after step S1 in the method of the present invention, showing the first connecting segment;

[0018] Figure 2 This is a top view of a portion of the winding wires after step S1 in the method of the present invention;

[0019] Figure 3 This is a schematic diagram of a portion of the winding wire from a certain perspective after step S2 in the method of the present invention, showing the first end;

[0020] Figure 4 This is a top view of a portion of the winding wires after step S2 in the method of the present invention;

[0021] Figure 5 This is a schematic diagram of a portion of the winding wire from a certain perspective after step S31 in the method of the present invention, showing the second end;

[0022] Figure 6 This is a schematic diagram of another view of the winding wire structure after step S31 in the method of the present invention;

[0023] Figure 7 This is a schematic diagram of the structure of a portion of the winding wire after step S32 in the method of the present invention, showing the second intermediate bend point.

[0024] Figure 8 This is a structural schematic diagram of a portion of the winding wires from another perspective after step S32 in the method of the present invention.

[0025] Figure 9 This is a schematic diagram of the structure of a portion of the winding wire from a certain perspective after step S4 in the method of the present invention.

[0026] Figure 10 This is a structural schematic diagram of a portion of the winding wires from another perspective after step S4 in the method of the present invention.

[0027] Figure 11 This is a front view of the winding wire after step S5 in the method of the present invention;

[0028] Figure 12 This is a front view of a portion of the winding wire after step S5 in the method of the present invention, showing the third connecting segment;

[0029] Figure 13 This is a front view of the winding wire after step S6 in the method of the present invention;

[0030] Figure 14 This is a front view of a portion of the winding wires after step S6 in the method of the present invention;

[0031] Figure 15 This is a top view of a portion of the winding wires after step S6 in the method of the present invention;

[0032] Figure 16 This is a front view of the winding wire after step S7 in the method of the present invention;

[0033] Figure 17 This is a top view of a portion of the winding wires after step S7 in the method of the present invention;

[0034] Figure 18 This is a front view of the winding wire after step S8 in the method of the present invention.

[0035] In the diagram: 1. Cable laying fixture, 11. Cable laying groove, 12. First layer winding groove, 13. Second layer winding groove, 2. First connecting section, 3. First top bending point, 31. First end, 32. Second end, 4. Second connecting section, 41. First intermediate bending point, 42. Second intermediate bending point, 5. Second top bending point, 51. Third end, 52. Fourth end, 6. Third connecting section, 7. Front view, 8. Side view, 9. First tilt angle. Detailed Implementation

[0036] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention. Those skilled in the art can make adjustments as needed to adapt to specific application scenarios.

[0037] It should be noted that in the description of this invention, terms such as "upper," "lower," "left," "right," "inner," and "outer," which indicate direction or positional relationships, are based on the direction or positional relationships shown in the accompanying drawings. These are used merely for ease of description and do not indicate or imply that the relevant devices or elements 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. Furthermore, ordinal numbers such as "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0038] Furthermore, it should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "installation" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0039] like Figures 1-12 As shown, this invention proposes a method for forming distributed waveform windings, which utilizes a wire-laying fixture 1 to bend the winding wires. Specifically, as... Figure 1 and 2 As shown, multiple wire feeding slots 11 are provided on both sides of the wiring fixture 1, forming a first layer of winding slots 12 and a second layer of winding slots 13, respectively. For ease of description, the length direction of the wiring fixture 1 is referred to as the X-axis direction, the width direction as the Y-axis direction, and the height direction as the Z-axis direction. Specifically, the waveform winding forming method of the present invention includes the following steps: S1: Fold the winding wire out the first connecting segment 2, and then place it on one side of the wiring fixture 1. Specifically, in Figures 1-12 In the embodiment, the wire is placed in a wire release slot 11 of the first layer winding slot 12; S2: Find the first top bending point 3, rotate the winding wire behind the first top bending point 3 around the Z-axis with the first top bending point 3 as the center point, and fold out the first end 31; S3: Rotate the winding wire behind the first top bending point 3 around the X-axis and fold out the second end 32 and the second connecting segment 4; S4: Rotate the winding wire behind the first top bending point 3 in the opposite direction according to the rotation direction in S2, so as to flatten the second connecting segment 4 to the other side of the wire laying fixture 1, that is, flatten it into a wire release slot 11 of the second layer winding slot 13; S5: Repeat S2-S4 to fold out several winding ends and connecting segments to complete the forming of a single winding wire.

[0040] Regarding step S1, it should be noted that although the description here is to fold the winding wire out of the first connecting segment 2 and then place it into the wire release slot 11 on the wiring fixture 1, this is not restrictive. Those skilled in the art can also interchange the order of the two operations as needed. That is, the winding wire can be placed into the wire release slot 11 on the wiring fixture 1 first, and then the first connecting segment 2 can be folded out. This adjustment does not deviate from the basic principle of the present invention and therefore will also fall within the protection scope of the present invention.

[0041] In this embodiment, to address the issue of easy damage to the insulating varnish film at the winding ends, fewer twisting processes are employed when forming the winding ends. The first top bending point 3 is twisted three times. First, it is twisted once in S2, folding out the first end 31 while simultaneously twisting the winding wire located on the upper part of the wiring fixture 1 to the other side, facilitating subsequent processing of the winding wire. Second, it is twisted once in S3 when folding out the second end 32. Finally, it is twisted in the opposite direction in S4, flattening the folded second end 32 and the second connecting section 4 onto the wiring fixture 1. Since the twists in S2 and S4 occur along the same axis in opposite directions without flipping, the damage to the insulating varnish film at the first top bending point 3 is minimal. Furthermore, because the two forward and reverse twists at the first top bending point 3 in this design ensure that the orientation of the front and side of the winding wire remains unchanged, the winding wire at other locations does not flip. Other intermediate bending points are only bent once without twisting, so the damage to the insulating varnish film at other locations is also minimal.

[0042] To address the issue of large space occupation at the ends, this design employs a two-layer winding groove design for the wiring fixture 1. The first connecting section 2 is placed on one side of the wiring fixture 1—the side where the first layer winding groove 12 is located. The second end 32 and the second connecting section 4 are flattened onto the other side of the wiring fixture 1—the side where the second layer winding groove 13 is located. The winding wires remain parallel to each other, without a layer-by-layer design. This avoids the space occupied by two winding wires nested together. Furthermore, the two-layer design allows the winding wires to enter the second layer without needing to avoid obstacles after exiting the first layer, further reducing the space occupied at the winding ends.

[0043] To address the issues of fixed span and inflexible wiring, this solution employs a sequential folding method for connecting sections and winding ends. This allows for easy adjustment of the span, enabling the span at the first winding end to differ from that at the second. Furthermore, this solution forms one winding wire first, followed by the second, third, and so on. Therefore, the number of winding wires can be adjusted according to actual needs, making it suitable for motors with any number of slots. Compared to existing technologies that form a fixed number of winding wires at once, this solution is more flexible, allowing for the design of different spans, winding wire numbers, and other parameters to suit different motors, thereby maximizing motor efficiency. Moreover, this solution is simple and flexible to operate; subsequent winding wire forming only requires repeating S2-S4 a specific number of times to complete the formation of a single winding.

[0044] Furthermore, such as Figure 2 and 9As shown, in this embodiment, in order to make the winding wires parallel to each other and in two layers, and to facilitate the placement of the winding wires, the first connecting segment 2 is placed in a certain wire release slot 11 of the first layer winding slot 12, and the second connecting segment 4 is placed in a certain wire release slot 11 of the second layer winding slot 13.

[0045] Furthermore, such as Figures 1-12 As shown, in this embodiment, steps S1-S5 are specifically as follows: Figures 1-2 As shown, S1 is: folding the winding wire out the first connecting segment 2, the entire winding wire is divided into the starting end ( Figure 1 The portion below the middle winding fixture 1), the first connecting section 2, and the remaining winding wires ( Figure 1 (the part above the middle cable tool 1), and as Figure 12 As shown, the angle between the first connecting segment 2 and the remaining winding wire is the first tilt angle 9. The magnitude of the first tilt angle 9 can be determined according to the structure of the target winding, and is usually taken in the range of 90 degrees to 150 degrees; for example Figures 3-4 As shown in S2, the first top bending point 3 is located according to the distance between the winding end and the first connecting section 2. Then, the winding wire behind the first top bending point 3 is rotated around the Z-axis at a certain angle (including but not limited to 90 degrees) with the first top bending point 3 as the center, and the first end 31 is folded out. Since it is rotated around the Z-axis, the winding wire at this point is bent in the horizontal direction. Compared with the "twisted" folding in the prior art, it causes less damage to the insulating varnish film. Moreover, after rotating around the Z-axis, the winding wire behind the first end 31 is located on one side of the second winding groove 13 and forms a certain angle with the second winding groove 13. Generally, 90 degrees can be selected. This not only facilitates the manufacturing space for subsequent bending, but also facilitates the subsequent forming of the second connecting section 4 into the second winding groove 13.

[0046] like Figures 5-8 As shown, similar to folding out the first connecting segment 2 in S1, in S3, any suitable method can be used to form the second end 32 and the second connecting segment 4 of the winding wire behind the first top bending point 3 in one go. Preferably, the angle between the formed second end 32 and the remaining winding wire is equal to the degree of the first tilt angle 9 mentioned above, that is, equal to the angle between the first connecting segment 2 and the first end 31, so that the angle of the second end 32 and the second connecting segment 4 does not need to be adjusted later. S4: Rotate the second end 32, the second connecting segment 4 and the remaining winding wire around the first top bending point 3 in the opposite direction to that in S2, and press the second connecting segment 4 into one of the wire release slots 11 in the second layer winding slot 13. As described above, in order to make the second connecting segment 4 fit smoothly into the second layer winding slot 13, when folding out the second end 32 and the second connecting segment 4 in S3, the second connecting segment 4 is set along the Z-axis direction by ensuring the bending angle of the second end 32 and the second connecting segment 4.

[0047] like Figures 9-12 As shown, step S5 specifically includes the following operations: Repeat S2-S4 to sequentially complete the forming of the remaining winding ends and connecting segments on the remaining winding wires. Specifically, find the second top bending point 5, rotate the remaining winding wires behind the second top bending point 5 around the Z-axis at a certain angle with the second top bending point 5 as the center, and fold out the third end 51. At this time, the remaining winding wires behind the second top bending point 5 are located on one side of the first layer winding slot 12, and the remaining winding wires form a certain angle with the first layer winding slot 12, so that the remaining winding wires and the first layer winding slot 12 form the operation space for subsequent bending. Then, fold out the fourth end 52 and the third connecting segment 6 in sequence, and then press the third connecting segment 6 into a wire release slot 11 in the first layer winding slot 12. Since the number of connecting segments and winding ends of different motors is different, repeat S2-S5 a specific number of times according to the actual situation to complete the forming of different single windings respectively.

[0048] Furthermore, such as Figures 13-18 As shown, after the first winding is formed, the method in this embodiment further includes the following steps: Figures 13-15 As shown, S6: Repeat S1 to fold out the first connecting segment 2 of the second winding wire. Then, offset the first connecting segment 2 of the second winding wire by n slots and place it into one of the placement slots 11 of the first layer winding slots 12. Then repeat S2-S5 to complete the forming of the second winding wire. The number of offsets can be determined according to actual needs and is not limited to the case of offsetting by one slot as shown in the figure. Figures 16-17 As shown, S7 involves repeatedly forming the third, fourth, and finally the last winding wire; as... Figure 18 As shown, finally, in step S8, the wiring fixture 1 can be removed. For example, two rod-shaped members can be inserted from the end to push the formed winding outward from the connecting sections on both sides, and then the wiring fixture 1 can be pulled out along the length direction. Of course, any other suitable method can be used to remove the wiring fixture 1, and the present invention does not impose any limitations on this.

[0049] Furthermore, in this embodiment, after bending the winding wire in S1 to form the first connecting segment 2 and placing it in the wire release groove 11, the angle formed by the bending between the first connecting segment 2 and the remaining winding wire is equal to the first inclination angle 9. This eliminates the need to adjust the direction of the remaining winding wire during subsequent processing, simplifying the forming steps. Preferably, as follows... Figure 12 As shown, the angle between the middle connecting segment and the adjacent end of each winding wire is equal to the first tilt angle 9, and the degree of the first tilt angle 9 is usually in the range of 90-150 degrees, depending on the expected winding end structure.

[0050] Furthermore, in S3 of this embodiment, the second end 32 and the second connecting segment 4 are formed by a two-step bending method, as shown below. Figures 5-6 As shown, specifically in step S31: Because the second end 32 is ultimately located below the first top bend point 3, the winding wire after the first top bend point 3 is rotated downwards in the X direction with the first top bend point 3 as the center, and then bent at the first intermediate bend point 41 after the first top bend point 3 to form the second end 32. Compared to rotating in other directions, this solution can minimize the number of operation steps and the degree of twisting of the winding wire. It should be noted that the bending operation in this solution can be performed in any suitable manner, including existing techniques.

[0051] Specifically, such as Figure 7 , 8 As shown in Figure 10, the connection point between the second connecting segment 4 and the second end 32 is the first intermediate bending point 41, and the connection point between the second connecting segment 4 and the third end 51 is the second intermediate bending point 42; after bending out the first intermediate bending point 41 in the previous step S31, as shown in Figure 10... Figures 7-8 As shown, S32 involves determining the position of the second intermediate bending point 42 based on the distance between the first intermediate bending point 41 and the second intermediate bending point 42. Then, using the second intermediate bending point 42 as the center point, the remaining winding wire is rotated around the X-axis to fold out the second connecting segment 4. At this point, the remaining winding wire, the second end 3, and the second connecting segment 4 are all located in the same plane. Therefore, during the subsequent rotation in S4, they can all be rotated onto the wiring fixture 1. Compared to rotating in other directions, this process is more efficient. Furthermore, as mentioned above, the angle between the second connecting segment 4 and the remaining winding wire is equal to the first tilt angle 9, so the angle of the remaining winding wire does not need to be adjusted during the subsequent forming process.

[0052] Furthermore, in this embodiment, in order to smoothly rotate the second connecting segment 4 into the placement slot 11 of the second layer winding groove 13, when the second connecting segment 4 is folded out, the bending angle of the second end 32 and the second connecting segment 4 is ensured to keep it parallel to the Z-axis direction. Specifically, firstly, it is ensured that the angle between the second end 32 and the second connecting segment 4 is equal to the first tilt angle 9, and at the same time, after the second end 32 is bent downward around the first top bending point 3 at a set angle, the second connecting segment 4 can remain parallel to the Z-axis direction.

[0053] Furthermore, in this embodiment, the winding wire is first leveled by a leveling device before being folded out of the first connecting section 2 or placed into the wiring fixture 1, to avoid unnecessary folds or other problems during subsequent bending. The leveling device can take any suitable form, and the present invention does not impose any restrictions on its specific structure.

[0054] Furthermore, such as Figures 1-2As shown, the winding wire of the present invention is a flat wire with a front side 7 and a side side 8. In this embodiment, the side side 8 is bent to form the first connecting segment 2, and the front side 7 is not bent. This allows the winding wire to not flip during the bending process. The front side 7 is used to place the wire release groove 11, and the width of the wire release groove 11 is consistent with the width of the front side 7 of the winding wire.

[0055] Furthermore, such as Figure 15 As shown, in this embodiment, the first top bending point 3 is bent three times to form an arc-shaped curved section. The length of this curved section is the distance between the first end 31 and the second end 32 along the Y-axis. This distance is usually slightly greater than the thickness between the first layer winding groove 12 and the second layer winding groove 13, so as to facilitate the embedding of each connecting segment into the wire release groove 11 and avoid the twisting and deformation of the winding end.

[0056] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will all fall within the scope of protection of the present invention.

Claims

1. A method for forming a distributed waveform winding, characterized in that, The method is implemented using a wiring fixture (1), which has multiple wire feeding grooves (11) on both sides to form a first layer of winding grooves (12) and a second layer of winding grooves (13). The length direction of the wiring fixture (1) is the X-axis direction, the width direction is the Y-axis direction, and the height direction is the Z-axis direction. The method includes the following steps: S1: Fold the winding wire out of the first connecting section (2) and then place it into a wire release slot (11) in the first layer winding slot (12) of the wiring fixture (1); or, first place the winding wire into a wire release slot (11) in the first layer winding slot (12) of the wiring fixture (1) and then fold out the first connecting section (2). S2: Find the first top bend point (3), rotate the winding wire behind the first top bend point (3) around the Z-axis at a certain angle with the first top bend point (3) as the center, and bend out the first end (31). At this time, the winding wire behind the first end (31) is located on one side of the second layer winding groove (13). S3: In the winding line after the first top bend point (3), find the first intermediate bend point (41) and the second intermediate bend point (42) respectively, and rotate them around the X-axis direction by a certain angle to fold out the second end (32) and the second connecting segment (4). S4: Rotate the part behind the first top bending point (3) in the opposite direction according to the rotation direction in S2, so as to flatten the second connecting section (4) into a wire release groove (11) in the second layer winding groove (13) of the wiring fixture (1); S5: Repeat S2-S4 to fold out several winding ends and connecting sections to complete the forming of a single winding wire.

2. The method for forming a distributed waveform winding according to claim 1, characterized in that, The specific steps of S1, S4, and S5 are as follows: S1: Fold the winding wire out of the first connecting segment (2) to make the entire winding wire into the starting end, the first connecting segment (2) and the remaining winding wire, and place the first connecting segment (2) into one of the wire release slots (11) in the first layer winding slot (12); S4: Rotate the second end (32), the second connecting section (4) and the remaining winding wire around the first top bend point (3) in the opposite direction to that in step S2, so as to press the second connecting section (4) into one of the wire release slots (11) in the second layer winding slot (13); S5: Repeat S2-S4, that is, find the second top bend point (5), rotate the remaining winding wire after the second top bend point (5) around the Z axis by a certain angle with the second top bend point (5) as the center, and bend out the third end (51). At this time, the remaining winding wire after the second top bend point (5) is located on one side of the first layer winding groove (12). Then fold out the fourth end (52) and the third connecting segment (6) in sequence, and then rotate in the opposite direction around the Z axis to press the third connecting segment (6) into a wire release groove (11) in the first layer winding groove (12); Repeat steps S2-S5 a specific number of times to complete the formation of a single winding.

3. The method for forming a distributed waveform winding according to claim 2, characterized in that, The method further includes the following steps: S6: Repeat S1 with the second winding wire to fold out the first connecting segment (2), then offset the first connecting segment (2) of the second winding wire by n slots and put it into one of the wire release slots (11) in the first layer winding slot (12). Then repeat S2-S5 to complete the forming of the second winding wire. S7: Repeat S6 a specific number of times to complete the forming of all winding wires; S8: Remove the cable tray fixture (1).

4. The method for forming a distributed waveform winding according to claim 2, characterized in that, The angle between the first connecting segment (2) and the first end (31) is equal to the angle between the second connecting segment (4) and the second end (32), the angle between the second connecting segment (4) and the third end (51), and the angle between the third connecting segment (6) and the fourth end (52); and / or The lengths of the first connecting segment (2), the second connecting segment (4), and the third connecting segment (6) are equal.

5. The method for forming a distributed waveform winding according to claim 2, characterized in that, Step S3 further includes the following steps: S31: Rotate the winding wire behind the first top bend point (3) downward around the X-axis with the first top bend point (3) as the center, and further rotate the winding wire behind it downward around the X-axis at the first intermediate bend point (41) to fold out the second end (32). S32: At the second intermediate bend point (42), the remaining winding wire is rotated upward around the X-axis to fold out the second connecting segment (4).

6. The method for forming a distributed waveform winding according to claim 2 or 5, characterized in that, The first connecting segment (2), the second connecting segment (4) and the third connecting segment (6) are parallel to the Z-axis direction.

7. The method for forming a distributed waveform winding according to claim 2, characterized in that, The winding wire is a flat wire with a front (7) and a side (8). In the method, the side (8) is bent to form the first connecting segment (2), the second connecting segment (4) and the third connecting segment (6). The front (7) is used to place the wire feeding groove (11).

8. The method for forming a distributed waveform winding according to claim 2, characterized in that, The distance between the first end (31) and the second end (32) along the Y-axis is greater than the thickness between the first layer winding groove (12) and the second layer winding groove (13).

9. A wiring fixture for the forming method of distributed waveform windings according to any one of claims 1 to 8, characterized in that, The wiring fixture (1) has multiple wire feeding slots (11) of the same size on both sides. The wire feeding slots (11) are used to accommodate the middle connecting section of the winding wire during the process of making the waveform winding.

10. The wiring fixture (1) for the forming method of distributed waveform windings according to claim 9, characterized in that, The wiring fixture (1) has a plate-shaped body, and the wire-laying grooves (11) are distributed on both sides of the plate-shaped body to form a first layer of winding grooves (12) and a second layer of winding grooves (13). The first layer of winding grooves (12) and the second layer of winding grooves (13) are respectively used to accommodate two adjacent intermediate connecting sections in each winding wire.

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