A flat wire stator pre-insertion device

Abstract

This invention relates to the field of motor assembly equipment technology and provides a flat wire stator pre-insertion device, comprising a pushing device, a winding device, a pressing device, a rotating device, and a top-mounting device arranged sequentially from top to bottom. A fixed ring is fixedly connected to a fixed base, and an annular groove is formed on the circumference of the fixed ring. A rotating ring is movably disposed within the annular groove, and a pushing electric cylinder is connected to the rotating ring, which drives the rotating ring to reciprocate within the annular groove of the fixed ring. A gear ring is provided on the outer ring of the turntable, and the gear ring meshes with a gear, which is fixedly connected to the output end of the rotary motor. The top-mounting device includes a vertical rod, a support base, and a top-mounting electric cylinder. The vertical rod is connected to the bottom of the rotating device, and the free end of the piston rod of the top-mounting electric cylinder is fixedly connected to the support base. This invention solves the problems of loose flat wires, the need for manual handling of the wire bundle, and the inability to individually control different pressing parts during the insertion process of the flat wire stator insertion device.

Description

Technical Field

[0001] This invention belongs to the technical field of motor assembly equipment, and particularly relates to a flat wire stator pre-insertion device. Background Technology

[0002] As one of the core components of new energy vehicles, the electric drive system has a significant impact on the performance of these vehicles, playing a crucial role in their power, economy, comfort, safety, reliability, and durability. The electric drive system of an electric vehicle mainly consists of four parts: the drive motor, the transmission, the power converter, and the controller. The drive motor is the core of the electric drive system; its performance and efficiency directly affect the performance of the electric vehicle. The size and weight of the drive motor and transmission also affect the overall efficiency of the vehicle. The motor's components include the stator, rotor, end caps, bearings, junction box, and terminals. The definition of a flat-wire motor specifically refers to a change in the shape of the conductors used in the stator windings, transforming from multiple thin round wires to several thick rectangular wires, commonly known as flat wire. Currently, flat-wire conductors are mainly used in large-scale motor equipment such as wind turbines and hydroelectric generators, and in recent years, they have been widely used in the generators of mid-to-high-end vehicles from foreign brands.

[0003] Flat-wire motors are increasingly being used in the electric vehicle industry. Flat-wire motors offer advantages such as high copper fill factor, improved heat dissipation in the motor windings, enhanced winding withstand voltage, and reduced winding end length, which in turn can increase the motor's torque density and power density.

[0004] During the assembly and production of flat wire motors, U-shaped flat wires need to be inserted into the stator. However, the slots on the stator are small, making it difficult to quickly insert the flat wires. Existing insertion devices first insert the flat wires into a fixture, and then remove the flat wires from the fixture and transfer them to the stator. Although this indirect insertion method is less difficult than direct insertion into the stator, it requires a special clamp to hold the flat wires during the transfer process. During clamping, the flat wires inevitably become tilted and loose, resulting in incomplete alignment with the slots on the stator, which causes inconvenience to the insertion operation. Moreover, different types of clamps are required for different types of flat wires. If there are multiple types of wires to be inserted, multiple types of clamping devices need to be prepared, increasing costs. Summary of the Invention

[0005] This invention provides a flat wire stator pre-insertion device, which aims to solve the problems that occur during the insertion process of flat wire stators, such as loose flat wires, the need for manual handling of the wire bundle before insertion, and the inability to control different pressing parts individually.

[0006] A flat wire stator pre-insertion device includes a pushing device, a winding device, a pressing device, a rotating device, and a top-wire device arranged sequentially from top to bottom.

[0007] The pushing device includes a fixedly installed pushing electric cylinder, a fixed ring, a rotating ring, a guide ring, and a pushing assembly;

[0008] The fixed ring is fixed to the fixed base. The fixed ring has an annular groove in its circumferential direction. The rotating ring is movably disposed in the annular groove. A push-pull electric cylinder is connected to the rotating ring. The push-pull electric cylinder can drive the rotating ring to reciprocate in the annular groove of the fixed ring. Several elongated grooves are opened along the circumferential direction of the rotating ring, and the elongated grooves are evenly distributed. The guide ring is fixedly disposed on the upper part of the rotating ring. Multiple grooves are opened along the guide ring. The push-pull component is disposed in the protrusion. The push-pull component can move in the elongated groove of the rotating ring and the groove of the guide ring under the drive of the push-pull electric cylinder.

[0009] The rotating device includes a gear, a turntable, and a rotary motor; the outer ring of the turntable is provided with a gear ring, the gear ring meshes with the gear, and the gear is fixedly connected to the output end of the rotary motor;

[0010] The top wire device includes a vertical rod, a support base, and a top wire electric cylinder; the vertical rod is connected to the bottom of the rotating device, and the free end of the piston rod of the top wire electric cylinder is fixed to the support base.

[0011] Based on the above technical solution, the inner ring sizes of the pushing device, the take-up device, the pressing device, and the rotating device are all the same.

[0012] Based on the above technical solution, the take-up device includes a take-up base plate, a take-up rotating disk, a take-up guide plate, a take-up slider, take-up teeth, and a take-up electric cylinder; the take-up base plate is recessed to form a groove, the take-up rotating disk is embedded in the groove, the take-up guide plate is fixedly connected to the take-up base plate, the take-up guide plate is provided with several grooves, the grooves are slidably connected to the take-up slider, the take-up slider is provided with corresponding first holes and second holes, the bottom of the take-up teeth is provided with guide posts, the guide posts are inserted into the second holes, the take-up rotating disk is provided with multiple holes around its circumference, a connector is inserted into the first hole, the connector passes through the take-up guide plate and slides in the hole of the take-up rotating disk, and the take-up rotating disk is fixedly connected to the take-up electric cylinder.

[0013] Based on the above technical solution, the following features are characterized in that: the pressing device includes a fixedly installed pressing electric cylinder, a cover plate, a pressing rotating disk, a pressing mechanism, and a pressing fixing plate; the pressing rotating disk is disposed on the pressing fixing plate, and several through holes are opened along the rotating disk; several sliding grooves are opened on the pressing fixing plate; the pressing mechanism is embedded in the sliding groove and slidably connected to the fixing plate, the pressing mechanism has a protrusion, the protrusion is inserted into the through hole of the pressing rotating disk, and the rotating disk is connected to the pressing electric cylinder.

[0014] Based on the above technical solution, the clamping mechanism is characterized in that: the clamping head includes a clamping head, a housing and a spring; the clamping head is fixed to the housing, the spring is disposed in the housing and its end is connected to the clamping head.

[0015] Beneficial effects

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: On the one hand, it realizes the automatic pre-insertion process in the insertion of flat wire stator windings, reducing manual labor and improving work efficiency. On the other hand, the winding, pushing, and pressing processes before stator insertion are all realized in one station, enabling the combing and insertion of different types of flat wires, thus reducing assembly costs. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only one embodiment of the present invention. For those skilled in the art, other embodiments can be derived from the provided drawings without creative effort.

[0018] Figure 1 : A schematic diagram of the structure of the present invention;

[0019] Figure 2 : Exploded view of the present invention;

[0020] Figure 3 : A schematic diagram of the pushing device structure described in this invention;

[0021] Figure 4 : Schematic diagram of the fixing ring of the pushing device of the present invention;

[0022] Figure 5 : A schematic diagram of the rotating ring of the pushing device of the present invention;

[0023] Figure 6 : Schematic diagram of the wire take-up device described in this invention;

[0024] Figure 7 : A schematic diagram of the installation of the take-up base plate and the take-up rotary disk of the take-up device of the present invention;

[0025] Figure 8 : A schematic diagram of the take-up slider and take-up teeth of the take-up device of the present invention;

[0026] Figure 9 : Enlarged view of the take-up teeth of the take-up device of the present invention;

[0027] Figure 10 : Schematic diagram of the wire pressing device (without wire pressing cylinder) of the present invention;

[0028] Figure 11 : Exploded view of the wire pressing device structure described in this invention;

[0029] Figure 12 : Schematic diagram of the wire pressing device (without cover plate) of the present invention;

[0030] Figure 13 : Schematic diagram of the clamping mechanism described in this invention;

[0031] Figure 14 : Cross-sectional view of the clamping mechanism described in this invention;

[0032] Figure 15 : Schematic diagram of the rotating device described in this invention;

[0033] Figure 16 : Schematic diagram of the top wire device described in this invention. Detailed Implementation

[0034] The present invention will be further described below with reference to the accompanying drawings and examples:

[0035] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0036] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" 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 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 based on the specific circumstances.

[0037] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not 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.

[0038] like Figures 1 to 2 As shown, a flat wire stator pre-insertion device is characterized by comprising a pushing device 31, a winding device 32, a pressing device 33, a rotating device 34, and a top-wire device 35 arranged sequentially from top to bottom.

[0039] The take-up device 32 includes a take-up base plate 321, a take-up rotary disk 322, a take-up guide plate 323, a take-up slider 324, take-up teeth 325, and a take-up electric cylinder 326.

[0040] The take-up base plate 321 is recessed to form a groove 3211. The take-up rotating disk 322 is embedded in the groove 3211. A take-up guide plate 323 is fixedly connected to the take-up base plate 321. The take-up guide plate 323 is provided with several grooves. The grooves are slidably connected to the take-up slider 324. The take-up slider 324 is provided with corresponding first holes 3241 and second holes 3242. The bottom of the take-up tooth 325 is provided with a guide post 3251. The guide post 3251 is inserted into the second hole 3242. The take-up rotating disk 322 is provided with multiple holes around its circumference. A connector is inserted into the first hole 3241. The connector passes through the take-up guide plate 323 and slides in the hole of the take-up rotating disk 322. A take-up electric cylinder 326 is fixedly connected to the take-up rotating disk 322.

[0041] The wire pressing device 33 includes a fixedly mounted wire pressing cylinder 331, a cover plate 332, a wire pressing rotating disk 333, a pressing mechanism 334, and a wire pressing fixing plate 335. The wire pressing rotating disk 333 is mounted on the wire pressing fixing plate 335, and several through holes are formed along the rotating disk 333. Several sliding grooves are formed on the wire pressing fixing plate 335. The pressing mechanism 334 is embedded in the sliding grooves and slidably connected to the fixing plate 335. The pressing mechanism 334 has a protrusion that is inserted into the through hole of the wire pressing rotating disk 333. The rotating disk 333 is connected to the wire pressing cylinder 331.

[0042] Furthermore, the clamping mechanism 334 includes a clamping head 3341, a housing 3342, and a spring 3343; the clamping head 3341 is fixed to the housing 3342, and the spring 3343 is disposed in the housing 3342, with its end connected to the clamping head 3341.

[0043] The rotating device 34 includes a gear 341, a turntable 342, and a rotary motor 343; the turntable 342 has a gear ring 344 on its outer ring, the gear ring 344 meshes with the gear 341, and the gear 341 is fixed to the output end of the rotary motor 343.

[0044] The top wire device 35 includes a vertical rod 351, a support base 353, and a top wire electric cylinder 352; the vertical rod 351 is connected to the bottom of the rotating device 34, and the support base 353 is fixedly connected to the free end of the piston rod of the top wire electric cylinder 352.

[0045] Preferably, the inner rings of the pushing device 31, the take-up device 32, the pressing device 33, and the rotating device 34 are all the same size.

[0046] In use, the robotic arm inserts the flat wire from above the pre-insertion device.

[0047] like Figures 6 to 9 As shown, first, the take-up device 32 starts working.

[0048] When the take-up cylinder 326 is in operation, the free end of the piston of the cylinder 326 extends out, driving the take-up rotating disk 322 to rotate. Because the holes on the take-up rotating disk 322 are distributed in an inclined direction around the circumference of the take-up rotating disk 322, the connecting piece slides on the rotating disk 322, causing the take-up slider 324 to slide back and forth in the groove of the take-up guide plate 323, driving the take-up teeth 325 to move back and forth, gradually gathering the flat line into the groove of each take-up tooth 325.

[0049] like Figures 3 to 5 As shown, the pushing device 31 operates, and the pushing assembly 315 opens, remaining in a non-closed state. At this time, the flat wire spreads out and tilts. Then, the pushing electric cylinder 311 starts operating, with its piston rod extending and driving the rotating ring 313 to rotate via the connecting block. This, in turn, drives the pushing assembly 315 to move towards the center of the rotating ring 313 or the guide ring 314. The pushing assembly 315 gradually closes, forming a closed ring. The flat wire located within the fixed ring 312, rotating ring 313, and guide ring 314 is pushed into an upright state. Then, the piston rod of the pushing electric cylinder 311 retracts, and the connecting block drives the rotating ring 313 to rotate in the opposite direction. The pushing assembly 315 moves towards the opposite direction of the center of the rotating ring 313 or the guide ring 314, gradually opening. When the extended end of the driving device 311 is fully retracted, the connecting part 3131 returns to its initial position, and the entire pushing process is completed.

[0050] like Figures 10 to 14 As shown, the wire pressing device 33 then operates. The wire pressing cylinder 331 drives the wire pressing rotating disk 333 to rotate. The pressing mechanism 334 has a protrusion that inserts into the through hole of the wire pressing rotating disk 333. The protrusion drives the pressing mechanism 334 to slide in the sliding groove of the wire pressing fixing plate 335, that is, the pressing mechanism 334 extends towards the center of the wire pressing rotating disk 333, pressing each flat wire. After the flat wire pressing process is completed, the wire pressing cylinder 331 operates, driving the wire pressing rotating disk 333 to rotate in the opposite direction, thereby driving the pressing mechanism 334 to retract. Then the pressing process is repeated, and so on, continuously pressing the outermost ring of flat wires of the stator. Multiple layers of flat wires can be pressed, so that the flat wires are pressed together layer by layer and closed into a ring shape. Such flat wires are not easy to loosen and are easy to handle and install.

[0051] Preferably, a spring 3343 is provided inside the clamping mechanism 334, which makes the clamping head 3341 more efficient when the clamping mechanism 334 clamps the flat wire.

[0052] After the above-mentioned wire feeding, pushing, and pressing processes, the robotic arm begins inserting the wires. After inserting each wire, as follows: Figure 15The rotating device 34 shown rotates by an angle, and the rotating motor 343 drives the gear 341 fixed on it to rotate, which in turn drives the turntable 342 to rotate. Each rotation angle makes the next hole that needs to be plugged in rotate to the same position as the previous hole.

[0053] When the robotic arm has inserted all the spools A in sequence, such as Figure 16 The top wire device 35 shown is in operation: the top wire electric cylinder 352 is working, lifting the support base 353, and the robot arm can pick up the entire spool A to complete the pre-insertion step.

[0054] The present invention has been described above by way of example, but the present invention is not limited to the specific embodiments described above. Any modifications or variations made based on the present invention shall fall within the scope of protection claimed by the present invention.

Claims

1. A flat wire stator pre-insertion device, characterized in that: It includes a pushing device (31), a winding device (32), a pressing device (33), a rotating device (34), and a top-mounting device (35) arranged from top to bottom. The pushing device (31) includes a fixedly installed pushing electric cylinder (311), a fixed ring (312), a rotating ring (313), a guide ring (314), and a pushing assembly (315). The fixed ring (312) is fixed to the fixed base (316). The fixed ring (312) has an annular groove in the circumferential direction. The rotating ring (313) is movably disposed in the annular groove. The rotating ring (313) is connected to the push cylinder (311). The push cylinder (311) can drive the rotating ring (313) to reciprocate in the annular groove of the fixed ring (312). Several elongated grooves are opened along the circumferential direction of the rotating ring (313). The elongated grooves are evenly distributed. The guide ring (314) is fixedly disposed on the upper part of the rotating ring (313). Several grooves are opened along the guide ring (314). The push assembly (315) is disposed in the protrusion. The push assembly (315) can move in the elongated groove of the rotating ring (313) and the groove of the guide ring (314) under the drive of the push cylinder (311). The rotating device (34) includes a gear (341), a turntable (342), and a rotary motor (343); the turntable (342) has a gear ring (344) on its outer ring, the gear ring (344) meshes with the gear (341), and the gear (341) is fixed to the output end of the rotary motor (343); The top wire device (35) includes a vertical rod (351), a support base (353), and a top wire electric cylinder (352); one end of the vertical rod (351) is connected to the bottom of the rotating device (34), and the other end is fixed to the support base (353); the free end of the piston rod of the top wire electric cylinder (352) is fixed to the support base (353). The take-up device (32) includes a take-up base plate (321), a take-up rotary disk (322), a take-up guide plate (323), a take-up slider (324), take-up teeth (325), and a take-up electric cylinder (326). The take-up base plate (321) is recessed to form a groove (3211), and the take-up rotating disk (322) is embedded in the groove (3211). A take-up guide plate (323) is fixedly connected to the take-up base plate (321). The take-up guide plate (323) is provided with several grooves. The grooves are slidably connected to the take-up slider (324). The take-up slider (324) is provided with a first hole (3241) and a second hole (3242) corresponding to the front and rear. The bottom of the take-up tooth (325) is provided with a guide post (3251). The guide post (3251) is inserted into the second hole (3242). The take-up rotating disk (322) is provided with multiple holes around its circumference. A connector is inserted into the first hole (3241). The connector passes through the take-up guide plate (323) and slides in the hole of the take-up rotating disk (322). A take-up electric cylinder (326) is fixedly connected to the take-up rotating disk (322). The wire pressing device (33) includes a fixedly installed wire pressing electric cylinder (331), a cover plate (332), a wire pressing rotating disk (333), a pressing mechanism (334), and a wire pressing fixing plate (335); the wire pressing rotating disk (333) is set on the wire pressing fixing plate (335), and several through holes are opened along the rotating disk (333); several sliding grooves are opened on the wire pressing fixing plate (335); the pressing mechanism (334) is embedded in the sliding groove and slidably connected to the fixing plate (335), the pressing mechanism (334) is provided with a protrusion, the protrusion is inserted into the through hole of the wire pressing rotating disk (333) and slides in the through hole, and the rotating disk (333) is connected to the wire pressing electric cylinder (331).

2. The flat wire stator pre-insertion device according to claim 1, characterized in that: The clamping mechanism (334) includes a clamping head (3341), a housing (3342), and a spring (3343); the clamping head (3341) is connected to the end of the housing (3342), and the spring (3343) is disposed inside the housing (3342), with its end connected to the clamping head (3341).

3. The flat wire stator pre-insertion device according to claim 1, characterized in that: The inner rings of the pushing device (31), the take-up device (32), the pressing device (33), and the rotating device (34) are all the same size.

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