A flat wire motor winding torsion device

Abstract

This invention provides a flat wire motor winding torsion device, comprising: a torsion assembly, which includes multiple torsion rings, one of which is rotatably disposed relative to the other; each torsion ring having multiple torsion grooves, which are disposed through the torsion ring along the axial direction of the torsion ring; and the torsion grooves being used to accommodate the flat wire winding to be torsion at the motor end. By configuring the torsion assembly, which includes multiple torsion rings, each with multiple torsion grooves for accommodating the flat wire winding to be torsion at the motor end, during operation, the torsion assembly controls the relative rotation of two adjacent torsion rings by a preset angle. After moving a preset distance along the axial direction of the motor, the torsion assembly is positioned within each torsion groove, and the ends of adjacent flat wire windings along the radial direction of the torsion ring overlap, effectively ensuring more precise positioning of the welding points after the flat wire winding is formed.

Description

Technical Field

[0001] This invention relates to the field of stator processing technology, and more specifically, to a flat wire motor winding torsion device. Background Technology

[0002] Currently, electric vehicle drive motors primarily use hairpin motors. To continuously improve motor efficiency and power, efforts are being made to reduce the height of the motor's ends, thereby reducing the axial dimension and increasing power density. Current hairpin motors use a torsion barrel to twist the windings and then weld the extended leads. These leads are generally too long, increasing the resistance and copper losses in the motor windings, resulting in low efficiency and wasted copper. Furthermore, the excessive length of the winding ends also hinders further increases in power density. Summary of the Invention

[0003] The main objective of this invention is to provide a flat wire motor winding torsion device to solve the problem of inaccurate welding points due to excessively long end lengths of motor windings in the prior art.

[0004] To achieve the above objectives, according to one aspect of the present invention, a flat wire motor winding torsion device is provided, comprising: a torsion assembly, the torsion assembly including a plurality of torsion rings, the outer diameter of the plurality of torsion rings being arranged to gradually increase outward along the geometric center direction of the torsion assembly, and the geometric centers of the plurality of torsion rings being arranged concentrically, one of adjacent torsion rings being rotatable relative to the other, each torsion ring having a plurality of torsion grooves, each torsion groove being arranged to extend through the axial direction of the torsion ring, the torsion grooves being used to accommodate the flat wire winding to be torsion at the end of the motor; wherein, during operation, while controlling the relative rotation of two adjacent torsion rings by a preset angle, the torsion assembly is controlled to move a preset distance along the axial direction of the motor, and after being located in each torsion groove, the ends of adjacent flat wire windings along the radial direction of the torsion rings are overlapped together.

[0005] Furthermore, the multiple torsion rings include a first torsion ring, a second torsion ring, and a third torsion ring. The outer peripheral wall of the first torsion ring is in contact with the inner peripheral wall of the second torsion ring, and the outer peripheral wall of the second torsion ring is in contact with the inner peripheral wall of the third torsion ring. Each torsion ring moves a preset distance along the axial direction of the motor via a guide rail assembly.

[0006] Furthermore, multiple twisting coils have the same number of layers as the flat wire winding to be twisted. The twisting coils are rotated by a servo motor, and adjacent twisting coils rotate in opposite directions. The rotation speed of each twisting coil is set differently.

[0007] Furthermore, the torsion ring includes: a first torsion abrasive, the first torsion abrasive including a first annular mold, the outer wall of the first annular mold having a plurality of first protrusions; a second torsion abrasive, the second torsion abrasive including a second annular mold, the inner wall of the second annular mold having a plurality of second protrusions; wherein, the first protrusions and the second protrusions are arranged in a one-to-one correspondence, the ends of the first protrusions and the ends of the second protrusions are arranged in close contact, and a torsion groove is formed between every two first protrusions and the second protrusions.

[0008] Furthermore, the first torsion grinding wheel and the second torsion grinding wheel are each driven by a servo motor.

[0009] Furthermore, multiple rolling cylinders are provided on the sidewalls of the first and second protrusions. When the torsion assembly is in operation, the rolling cylinders are used to prevent the flat wire winding from rubbing against the torsion groove.

[0010] Furthermore, grease is applied between the rolling cylinder and the flat wire winding.

[0011] Furthermore, the width of the slot at the end of the torsion groove closer to the stator core is smaller than the width of the slot at the end of the torsion groove farther from the stator core.

[0012] Furthermore, the flat wire motor winding torsion device also includes: stator clamps, of which there are two, which are arranged opposite each other on both sides of the stator core. The stator clamps are used to prevent the stator core from rotating during the torsion assembly operation.

[0013] Furthermore, the stator clamp includes: a clamping part, the first side of which is in contact with the outer wall of the stator core; and a fixing part, which is connected to the second side of the clamping part and is used to fix the clamping part (62).

[0014] By applying the technical solution of this invention, a torsion assembly is provided, comprising multiple torsion rings. The outer diameter of the multiple torsion rings gradually increases outward along the geometric center direction of the torsion assembly. Each torsion ring has multiple torsion grooves for accommodating the flat wire windings to be torsion at the motor end. During operation, as the torsion assembly controls the relative rotation of two adjacent torsion rings by a preset angle, and after moving a preset distance along the axial direction of the motor, the torsion assembly is positioned within each torsion groove, and the ends of adjacent flat wire windings overlap along the radial direction of the torsion rings. This effectively ensures a more precise welding point position after the flat wire windings are formed. Attached Figure Description

[0015] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0016] Figure 1 A schematic diagram of a first embodiment of a torsion assembly according to the present invention is shown;

[0017] Figure 2 The present invention is shown Figure 1 A magnified view of a section at point A in the middle;

[0018] Figure 3 A schematic diagram of a first embodiment of a flat wire motor winding torsion device according to the present invention is shown.

[0019] Figure 4 A schematic diagram of a second embodiment of a flat wire motor winding torsion device according to the present invention is shown;

[0020] Figure 5 A schematic diagram of a third embodiment of a flat wire motor winding torsion device according to the present invention is shown;

[0021] Figure 6 A schematic diagram of a fourth embodiment of a flat wire motor winding torsion device according to the present invention is shown;

[0022] Figure 7 A schematic diagram of an embodiment of a flat wire winding according to the present invention is shown.

[0023] The above figures include the following reference numerals:

[0024] 1. Torsion assembly;

[0025] 10. First torsion ring; 11. First torsion mold; 12. First annular mold; 13. First protrusion; 14. Second torsion mold; 15. Second annular mold; 16. Second protrusion; 17. Rolling cylinder;

[0026] 20. Second twist;

[0027] 30. The third twisting loop;

[0028] 40. Torsion groove; 41. Flat wire winding;

[0029] 50. Welded ball;

[0030] 60. Stator clamp; 61. Stator core; 62. Clamping part; 63. Fixing part. Detailed Implementation

[0031] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0032] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0033] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate so that the embodiments of this application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0034] Exemplary embodiments according to this application will now be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. It should be understood that these embodiments are provided so that the disclosure of this application is thorough and complete, and that the concept of these exemplary embodiments is fully conveyed to those skilled in the art. In the drawings, for clarity, the thickness of layers and regions may be exaggerated, and the same reference numerals are used to denote the same devices, and therefore their description will be omitted.

[0035] Combination Figures 1 to 7 As shown, according to a specific embodiment of this application, a flat wire motor winding torsion device is provided.

[0036] Specifically, a flat wire motor winding torsion device includes: a torsion assembly 1, which includes multiple torsion rings. The outer diameter of the multiple torsion rings gradually increases outward along the geometric center direction of the torsion assembly 1, and the geometric centers of the multiple torsion rings are concentric. One of the adjacent torsion rings is rotatable relative to the other. Each torsion ring is provided with multiple torsion grooves 40, and each torsion groove 40 is arranged to pass through the axial direction of the torsion ring. The torsion grooves 40 are used to accommodate the flat wire winding 41 to be torsion at the end of the motor. During operation, the torsion assembly 1 controls the relative rotation of two adjacent torsion rings by a preset angle. After the torsion assembly 1 moves a preset distance along the axial direction of the motor, it is located in each torsion groove 40, and the ends of the adjacent flat wire windings 41 are overlapped together along the radial direction of the torsion ring.

[0037] In this embodiment, as Figure 1 , Figure 3 As shown, a torsion assembly is provided, comprising multiple torsion rings. The outer diameter of these rings gradually increases outward from the geometric center of the torsion assembly. Each torsion ring contains multiple torsion grooves to accommodate the flat wire windings to be torsion at the motor end. During operation, the torsion assembly controls the relative rotation of two adjacent torsion rings by a preset angle. After moving a preset distance along the axial direction of the motor, the torsion assembly is positioned within each torsion groove, and the ends of adjacent flat wire windings overlap along the radial direction of the torsion rings. This effectively ensures more precise positioning of the welding points after the flat wire windings are formed.

[0038] Furthermore, the multiple torsion rings include a first torsion ring 10, a second torsion ring 20, and a third torsion ring 30. The outer peripheral wall of the first torsion ring 10 is in contact with the inner peripheral wall of the second torsion ring 20, and the outer peripheral wall of the second torsion ring 20 is in contact with the inner peripheral wall of the third torsion ring 30. Each torsion ring moves a preset distance along the axial direction of the motor via a guide rail assembly. This arrangement ensures that the multiple torsion rings are stably aligned with the flat wire winding and guarantees that the multiple torsion rings can rise synchronously via the guide rail assembly, effectively preventing some torsion rings from falling off midway.

[0039] Furthermore, multiple twisting coils have the same number of layers as the flat wire winding to be twisted (41 layers). The twisting coils are rotated by a servo motor, with adjacent twisting coils rotating in opposite directions. The rotation speeds of each twisting coil are set differently. This configuration is as follows: Figure 5 As shown, this allows the ends of the flat wire windings 41 on the adjacent two layers of torsion coils to be stably aligned and accurately welded by welding balls 50.

[0040] like Figure 2As shown, the torsion ring includes: a first torsion mold 11, which includes a first annular mold 12, the outer wall of which is provided with a plurality of first protrusions 13; and a second torsion mold 14, which includes a second annular mold 15, the inner wall of which is provided with a plurality of second protrusions 16. The first protrusions 13 and second protrusions 16 are arranged in a one-to-one correspondence, with the ends of the first protrusions 13 and the ends of the second protrusions 16 fitting together, forming a torsion groove 40 between every two first protrusions 13 and second protrusions 16. This arrangement ensures that the processing of the first torsion mold 11 and the second torsion mold 14 is more convenient, and that the flat wire winding 41 can be more accurately installed into the torsion groove 40.

[0041] Furthermore, the first torsion mold 11 and the second torsion mold 14 are each driven by a servo motor. This arrangement ensures that multiple torsion rings can rise synchronously via the guide rail assembly, effectively preventing some torsion rings from falling off midway.

[0042] Specifically, multiple rolling cylinders 17 are provided on the sidewalls of the first protrusion 13 and the second protrusion 16. During operation of the torsion assembly 1, the rolling cylinders 17 are used to prevent friction between the flat wire winding 41 and the torsion groove 40. In this embodiment, the rolling cylinders 17 are semi-circular protrusions from the inner surface of the groove and can rotate. This design avoids sliding friction between the surface of the groove and the surface of the flat wire winding 41 during the torsion process, which could damage the surface coating of the flat wire winding 41 and lead to insulation failure.

[0043] Furthermore, grease is applied between the rolling cylinder 17 and the flat wire winding 41. This arrangement improves the lubrication efficiency between the rolling cylinder 17 and the flat wire winding 41, effectively preventing damage to the enamel coating on the flat wire winding 41 and thus preventing insulation failure.

[0044] Furthermore, the width of the slot opening at the end of the torsion slot 40 near the stator core 61 is smaller than the width of the slot opening at the end of the torsion slot 40 away from the stator core 61. The torsion slot 40, through its special design of being wider at the deeper end and narrower at the shallower end, achieves convenience during torsion, allowing the flat wire winding 41 to have a certain amount of room to move during torsion deformation, thus protecting the winding.

[0045] In another embodiment of this application, the flat wire motor winding torsion device further includes: two stator clamps 60, which are arranged opposite each other on both sides of the stator core 61. The stator clamps 60 are used to prevent the stator core 61 from rotating during the operation of the torsion assembly 1. In this embodiment, the stator clamps 60 are composed of two arc-shaped clamping devices with the same outer diameter as the stator core, which firmly fix the stator during torsion. This arrangement effectively ensures that the stator core 61 does not shift when the torsion assembly 1 is working.

[0046] Furthermore, the stator clamp 60 includes: a clamping part 62, the first side of which is in contact with the outer wall of the stator core 61; and a fixing part 63, which is connected to the second side of the clamping part 62 and is used to fix the clamping part 62. This arrangement effectively ensures the stability of the stator clamp 60 and prevents displacement of the stator core 61.

[0047] In another embodiment of this application, the flat wire winding 41, after being flared, is clamped and fixed by the stator clamp 60. The position of the flared portion of each layer of flat wire winding 41 is the same as the position of the torsion groove 40 of the corresponding layer of torsion coil. Then, the torsion coil moves downward under the cooperation of the servo motor and the guide rail, as... Figure 4 As shown, each flat wire winding 41 is inserted into each corresponding torsion slot 40.

[0048] The flat wire winding 41 is located within the torsion groove 40, the groove width of which is greater than the wire width of the flat wire winding 41. As the torsion head mold rotates, it moves upwards, clamping and fixing the motor stator in place. Figure 5 As shown, the torsion groove 40 is offset to the right and upward. Under the force of the rolling cylinders on the multiple inner surfaces of the torsion groove 40, the flat wire winding 41 simultaneously moves upward along with the torsion head mold, as... Figure 6 As shown, the flat wire winding 41 is twisted and formed. Two windings of different layers and different twisting directions are twisted and then overlapped together, and can then be welded together.

[0049] The torsion assembly 1 has a multi-layer concentric circle structure, and the number of layers depends on the number of layers of the flat wire motor to be torsion. During torsion, the first turn rotates in the opposite direction to the second turn, the third turn rotates in the fourth turn, the fifth turn rotates in the sixth turn, and so on, ultimately achieving the torsion-shaped flat wire winding, so that the windings of different layers overlap together.

[0050] As can be seen from the above description, the embodiments of the present invention achieve the following technical effects:

[0051] 1) By eliminating straight sections at the winding ends after twisting and forming, the end height of the flat wire motor is significantly reduced, thus decreasing copper usage and lowering motor costs. Simultaneously, it reduces motor copper losses, thereby improving motor efficiency.

[0052] 2) By designing the groove of the torsion mold to allow it to roll with the winding surface, the present invention achieves no damage to the surface of the winding after the winding is formed, and reduces the friction between the groove surface of the torsion mold and the surface of the enameled wire, thus protecting the enamel film.

[0053] 3) This invention achieves convenience during torsion by adopting a special design with a wide opening at the deep end and a narrow opening at the shallow end, allowing the winding to have a certain amount of room to move when torsion and deform, thus protecting the enameled flat wire.

[0054] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0055] In addition to the above, it should be noted that the terms "one embodiment," "another embodiment," and "embodiment" used in this specification refer to specific features, structures, or characteristics described in connection with that embodiment, which are included in at least one embodiment described in the general description of this application. The appearance of the same expression in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in connection with any embodiment, the intention is to suggest that implementing such a feature, structure, or characteristic in conjunction with other embodiments also falls within the scope of this invention.

[0056] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0057] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A flat wire motor winding twisting device, characterized by, include: A torsion assembly (1) includes multiple torsion rings. The outer diameter of the multiple torsion rings gradually increases outward along the geometric center direction of the torsion assembly (1), and the geometric centers of the multiple torsion rings are concentric. One of the adjacent torsion rings is rotatable relative to the other. Each torsion ring is provided with multiple torsion grooves (40). Each torsion groove (40) is provided through the axial direction of the torsion ring. The torsion grooves (40) are used to accommodate the flat wire winding (41) to be torsion at the end of the motor. During operation, the torsion assembly (1) controls the relative rotation of two adjacent torsion rings by a preset angle. After the torsion assembly (1) moves a preset distance along the axial direction of the motor, it is located in each torsion groove (40), and the ends of adjacent flat wire windings (41) along the radial direction of the torsion rings overlap together. The plurality of torsion rings include a first torsion ring (10), a second torsion ring (20) and a third torsion ring (30). The outer peripheral wall of the first torsion ring (10) is in contact with the inner peripheral wall of the second torsion ring (20), and the outer peripheral wall of the second torsion ring (20) is in contact with the inner peripheral wall of the third torsion ring (30). Each torsion ring moves a preset distance along the axial direction of the motor via a guide rail assembly. The multiple twisting coils have the same number of layers as the flat wire winding (41) to be twisted. The twisting coils are rotated by a servo motor. The two adjacent twisting coils rotate in opposite directions. The rotation speed of each twisting coil is set differently. The torsion coil includes: The first torsion abrasive (11) includes a first annular mold (12), and the outer wall of the first annular mold (12) is provided with a plurality of first protrusions (13). The second torsion abrasive (14) includes a second annular mold (15), and the inner wall of the second annular mold (15) is provided with a plurality of second protrusions (16). The first protrusion (13) and the second protrusion (16) are arranged in a one-to-one correspondence. The end of the first protrusion (13) and the end of the second protrusion (16) are arranged in close contact. The torsion groove (40) is formed between every two first protrusions (13) and second protrusions (16). The first torsional abrasive (11) and the second torsional abrasive (14) are each driven by a servo motor.

2. Flat wire motor winding twisting device according to claim 1, characterized in that The first protrusion (13) and the second protrusion (16) are provided with a plurality of rolling cylinders (17). When the torsion assembly (1) is in operation, the rolling cylinders (17) are used to prevent the flat wire winding (41) from rubbing against the torsion groove (40).

3. Flat wire motor winding twisting device according to claim 2, characterized in that The rolling cylinder (17) and the flat wire winding (41) are coated with grease.

4. The flat wire motor winding twisting device of claim 2, wherein The width of the slot at the end of the torsion groove (40) near the stator core (61) is smaller than the width of the slot at the end of the torsion groove (40) away from the stator core (61).

5. A flat wire motor winding twisting device according to claim 4, characterized in that The flat wire motor winding torsion device further includes: Stator clamps (60), there are two stator clamps, the two stator clamps (60) are arranged opposite each other on both sides of the stator core (61), the stator clamps (60) are used to prevent the stator core (61) from rotating during the operation of the torsion assembly (1).

6. A flat wire motor winding twisting device according to claim 5, characterized in that The stator clamp (60) includes: The clamping part (62) has its first side in contact with the outer wall of the stator core (61); The fixing part (63) is connected to the second side of the clamping part (62) and is used to fix the clamping part (62).

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