Bending method of linear edge end overall bending tool based on tower coil

Abstract

The application discloses a kind of based on tower coil linear edge end integral bending tool bending method, greatly improve the forming quality of tower coil integral bending, belong to motor manufacturing field;Linear edge embedding groove (4) is arranged between front side vertical plate (2) and rear side vertical plate (3) on tooling bottom plate (1), bottom support intermediate pad (5) is fixedly arranged in the groove bottom of linear edge embedding groove (4), bending block embedding recess chamber (7) is arranged in the top end surface both sides end of front side vertical plate (2) and the top end surface both sides end of rear side vertical plate (3), and "Z" shape bending down surface (10) is arranged on the bottom end surface in bending block embedding recess chamber, bending down horizontal strip plate (11) connected with press is arranged directly above the slot of linear edge embedding groove (4), and pressing rectangular block (12) is arranged in the both ends of bending down horizontal strip plate;Coil integral forming quality is high.

Description

Technical Field

[0001] This invention relates to a rotor magnetic pole with a salient pole structure for an electric motor, and particularly to a tooling and bending method for integrally bending the straight edge of the tower-shaped coil of the rotor magnetic pole with a salient pole structure. Background Technology

[0002] The rotor poles of a synchronous generator are generally divided into two types: salient pole rotor poles and non-salient pole rotor poles. In a non-salient pole rotor pole configuration, the poles are located inside the rotor core. On the outer circumference of the rotor core, pole coil slots are provided for each pole. A tower-shaped pole coil is embedded in these slots. When this tower-shaped coil is energized, it forms the rotor pole. Existing tower-shaped coils are typically made of electromagnetic wire, wound and stacked into a tower shape. This entire coil is then layered and embedded turn by turn into the pole coil slots. Finally, the connection between the coils forms the pole winding. When the entire tower-shaped coil is embedded in the corresponding slot of the rotor core, poles extending from the core are formed at both ends of the rotor core. The outer magnetic pole winding ends; when the motor rotor rotates, the winding ends are subjected to centrifugal force and swing outward in the radial direction, which can easily cause the winding ends to loosen or shift, resulting in winding end breakage or short circuit, leading to the scrapping of the entire winding. This phenomenon is particularly serious for high-speed, high-power motors. To overcome this defect, the existing technology generally sets an annular fastening device on the outside of the winding ends to tighten the winding ends and prevent damage to the winding ends. In order to install the fastening device, those skilled in the art generally design the ends of the tower-shaped coil to be bent inward, so that the coil ends shrink towards the center of the circle, making room for the installation of the winding end fastening device.

[0003] A tower-shaped coil is a rectangular coil composed of two parallel straight sides and two connecting sides. Both ends of the straight sides need to be bent inwards. Since the entire tower-shaped coil is composed of multiple turns of coiled electromagnetic wire stacked together, sometimes with dozens of turns, and the electromagnetic wire is relatively narrow, the resulting stacked coils form a considerable height. Therefore, specialized bending fixtures are required when bending the straight sides. During the bending process, the challenge of preventing the stacked coils from diverging must be overcome. Furthermore, ensuring symmetrical bending at both ends of the straight sides and preventing coil deformation during bending is another problem. Because the electromagnetic wire is typically flat copper wire, springback occurs during bending. Controlling the amount of springback to achieve efficient bending is also a problem that needs to be solved on-site, especially when mass-producing tower-shaped coils. More urgent; the existing technology for bending the straight side of the tower coil is carried out in the following way: the coil is divided into several groups according to the total number of turns of the coil, each group of coils is bent separately, and then the bent coils are combined together to form a tower coil after bending. Then the whole coil is embedded into the iron core one turn at a time. This method of bending each group of coils separately has the following problems: (1) The method of bending the coils in groups has a large number of bending times, which increases the probability of coil breakage when bending. At the same time, there is also the problem of low bending efficiency; (2) The method of bending the coils in groups has poor bending consistency among the coils. When the whole coil is combined, the forming quality is poor and repeated repairs are required; (3) The operation of bending in groups cannot control the springback of the coil after bending. The tower coil formed after combining the coils with different springback is not of high forming quality. Summary of the Invention

[0004] This invention provides a bending method based on a bending fixture for the straight edge of a tower-shaped coil, which greatly improves the forming quality of the overall bending of the tower-shaped coil and increases the bending efficiency.

[0005] The present invention solves the above technical problems through the following technical solutions:

[0006] The overall concept of this invention is as follows: A fixture is designed to simultaneously bend both ends of the straight edge of an integral tower-shaped coil. This fixture is equipped with a straight edge embedding groove that provides front and rear positioning for the stacked straight edges of the integral tower-shaped coil. At the bottom of the straight edge embedding groove, a bottom support intermediate pad formed by bending both ends of the straight edge is provided. The straight edge embedding groove is composed of two parallel front and rear clamping plates. At the top sides of the front and rear clamping plates, bending pressure block embedding chambers are combined and arranged. On the bottom end face of the bending pressure block embedded in the mating chamber, a zigzag bending downward pressing surface is provided. Directly above the straight edge embedding groove, a bending downward pressing strip plate connected to the press is provided. The press performs bending downward pressing on both ends of the straight edge of the tower coil through the bending downward pressing strip plate. At both ends of the bending downward pressing strip plate, there are stepped downward pressing rectangular blocks. The stepped downward pressing rectangular blocks are pressed down first into the bending pressure block embedded in the mating chamber, and then the entire assembly placed on the bottom support intermediate pad in the straight edge embedding groove is pressed down. The straight edge of the tower-shaped coil is bent and pressed down. A zigzag downward protrusion is provided on the bottom surface of the pressing rectangular block. The downward pressure of this zigzag protrusion simultaneously bends and presses down both ends of the straight edge of the entire tower-shaped coil. At the same time, the bending pressing strip presses down and positions the middle of the straight edge, overcoming the problem of the middle of the straight edge easily arching upwards during the downward bending process. This invention creatively utilizes the fit between the pressing rectangular block and the bending pressing block embedded in the mating chamber. During the downward bending process, it achieves limitation of the downward pressure in the left-right and front-back directions, overcoming the defect of inter-turn coil slippage and downward pressure reversal caused by multi-turn coil stacking under downward pressure. This ensures the overall forming quality of the straight edge of the coil. Furthermore, by controlling the amount of the zigzag downward protrusion on the bottom surface of the pressing rectangular block, the problem of springback control after bending and pressing the straight edge is solved, greatly improving the bending forming efficiency of the straight edge.

[0007] An integral bending fixture for the straight edge end of a tower-shaped coil for a salient-pole rotor magnetic pole includes a fixture base plate and a tower-shaped coil. A straight edge is provided on the tower-shaped coil. A front upright plate and a rear upright plate are fixedly arranged parallel to each other on the fixture base plate. A straight edge embedding groove is provided between the front and rear upright plates. A bottom support intermediate pad is fixedly provided at the bottom of the straight edge embedding groove. A zigzag bending support step is provided on both sides of the top surface of the bottom support intermediate pad. Bending pressure block embedding grooves are provided on both sides of the top surface of the front and rear upright plates. A bending pressure block embedding groove is provided on the bottom surface of the bending pressure block embedding groove. The device has a zigzag-shaped bending pressing surface. On the top surface of the bottom support intermediate pad plate embedded in the straight edge groove, the straight edge of the tower-shaped coil is placed. Directly above the groove opening of the straight edge embedding groove, a bending pressing horizontal strip plate connected to the press is set. At both ends of the bending pressing horizontal strip plate, there are pressing rectangular blocks. The bottom surface of the pressing rectangular blocks has a zigzag downward protrusion. When the bending pressing horizontal strip plate is pressed into the groove opening of the straight edge embedding groove, the pressing rectangular blocks are embedded in the bending pressing block embedding groove chamber. Furthermore, the zigzag downward protrusion on the bottom surface of the pressing rectangular blocks is pressed against the end of the straight edge of the tower-shaped coil.

[0008] On the bent and pressed horizontal strip plate outside the pressing rectangular block, there is an inverted U-shaped limiting fork at the end of the straight edge. When the bent and pressed horizontal strip plate is pressed down into the slot of the straight edge embedding groove, the inverted U-shaped limiting fork at the end of the straight edge is inserted into the end of the straight edge of the tower coil. A pressing limiting eave is provided at the top of the pressing rectangular block.

[0009] A bending method based on a fixture for integrally bending the straight edge of a tower-shaped coil includes a fixture base plate and a tower-shaped coil. A straight edge is provided on the tower-shaped coil. A front upright plate and a rear upright plate are fixedly fixed parallel to each other on the fixture base plate. A straight edge embedding groove is provided between the front and rear upright plates. A bottom support intermediate pad is fixedly provided at the bottom of the straight edge embedding groove. A zigzag bending support step is provided on both sides of the top surface of the bottom support intermediate pad. A zigzag bending support step is provided on both sides of the top surface of the front upright plate. Both ends of the top surface of the end and rear side upright plate are provided with bending pressure block embedding groove chambers. On the bottom end surface of the bending pressure block embedding groove chamber, a zigzag bending downward pressing surface is provided. Above the groove opening of the straight edge embedding groove, a bending downward pressing horizontal strip plate connected to the press is provided. At both ends of the bending downward pressing horizontal strip plate, a downward pressing rectangular block is provided. On the bottom surface of the downward pressing rectangular block, a zigzag downward protrusion is provided. A downward pressing limiting eave is provided at the top of the downward pressing rectangular block; the feature is the following steps;

[0010] Step 1: Place the straight edge of the entire tower-shaped coil into the straight edge embedding groove set between the front and rear upright plates, and place the lower end of the straight edge on the top surface of the bottom support middle pad.

[0011] The second step involves controlling the bending and pressing horizontal strip plate connected to the press to press down, so that the bending and pressing horizontal strip plate enters the groove of the straight edge embedding groove. At the same time, the pressing rectangular block is embedded in the bending pressure block embedded in the groove chamber set between the front and rear upright plates. The bending and pressing horizontal strip plate continues to press down, and the "Z"-shaped downward protrusion set on the bottom surface of the pressing rectangular block presses against the end of the straight edge, so that it deforms to form the right end bend and the left end bend respectively.

[0012] Step 3: When the pressure limiting eaves set at the top of the pressure rectangular block on the bending and pressing horizontal strip plate come into contact with the top surface of the front vertical plate, the bending and pressing horizontal strip plate stops pressing and the pressure remains unchanged for 10 minutes.

[0013] The fourth step involves controlling the rise of the horizontal strip plate connected to the press, thereby completing the simultaneous bending of both ends of one straight side of the tower coil.

[0014] Step 5: Remove the straight edge of the tower coil from the straight edge insertion slot. Then, put the other straight edge of the tower coil into the straight edge insertion slot. Repeat steps 1 to 4 to complete the simultaneous bending of both ends of the other straight edge of the tower coil.

[0015] The maximum height of the downward protrusion in the zigzag shape on the bottom surface of the pressing rectangular block is two millimeters greater than the bending depth of the right end, in order to overcome the springback after bending the straight edge.

[0016] This invention abandons the traditional method of bending and pressing tower-shaped coils multiple times. The coil can be bent and formed by 1-2 overall bending, which reduces the probability of coil insulation damage when bending the electromagnetic wire. The overall coil forming quality is high, which greatly improves bending efficiency and overcomes the problem of serious waste of precious metal raw materials for electromagnetic wire, thereby reducing the manufacturing cost of motor. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall bending fixture of the present invention;

[0018] Figure 2 This is a schematic diagram of the overall bending fixture of the present invention after the front side upright plate 2 is removed;

[0019] Figure 3 This is a diagram showing the fit between the straight edge 9 and the bottom support intermediate pad 5 of the present invention;

[0020] Figure 4 This is a diagram showing the fit between the U-shaped limiting fork 15 at the end of the straight edge and the end of the straight edge 9 of the present invention.

[0021] Figure 5 This is a schematic diagram of the structure of the bent and pressed horizontal strip plate 11 of the present invention when it is pressed into place;

[0022] Figure 6 This is a schematic diagram of the structure of the tower-shaped coil 8 after the two straight ends are bent. Detailed Implementation

[0023] The present invention will now be described in detail with reference to the accompanying drawings:

[0024] A fixture for integrally bending the straight edge end of a tower-shaped coil for a salient-pole rotor magnetic pole includes a fixture base plate 1 and a tower-shaped coil 8. The tower-shaped coil 8 is integrally wound, and its two straight edges 9 are straight. A front upright plate 2 and a rear upright plate 3 are fixedly and parallel to each other on the fixture base plate 1, with the top surfaces of the two upright plates in the same plane. A straight edge embedding groove 4 is provided between the front upright plate 2 and the rear upright plate 3. When the straight edge 9 of the tower-shaped coil 8 is placed into the straight edge embedding groove 4, the front upright plate 2 and the rear upright plate 3 limit the front and rear sides of the straight edge 9. A bottom support is fixedly provided at the bottom of the straight edge embedding groove 4. The intermediate pad 5 has zigzag-shaped bending support steps 6 on both sides of its top. These zigzag-shaped bending support steps 6 form the bottom support for the bent and pressed ends of the straight edge 9. Bending block embedding groove chambers 7 are provided on both sides of the top surface of the front upright plate 2 and the top surface of the rear upright plate 3. Each bending block embedding groove chamber 7 is formed by the relative combination of a groove between the top surface of the front upright plate 2 and the rear upright plate 3 and the top surface of the rear upright plate 3 and the front upright plate 3. A straight edge embedding groove 4 is provided between these two grooves. A zigzag-shaped support step 6 is provided on the bottom surface of the bending block embedding groove chamber 7. The bottom support plate 5 of the straight edge embedded groove 4 of the T-shaped bending pressing surface 10 has a straight edge 9 of the tower-shaped coil 8 placed on its top surface. Above the opening of the straight edge embedded groove 4, a bending pressing horizontal strip plate 11 connected to the press is provided. The bending pressing horizontal strip plate 11 is connected to the downwardly extending output shaft of the press, controlling the downward extension of the press's output shaft to achieve vertical pressing of the bending pressing horizontal strip plate 11. At both ends of the bending pressing horizontal strip plate 11, pressing rectangular blocks 12 are provided. A zigzag downward protrusion 13 is provided on the bottom surface of the pressing rectangular block 12. The pressing rectangular block 12 is connected to the bending... The pressure block is embedded in the groove chamber 7. When the bending and pressing horizontal strip plate 11 is pressed down into the groove of the straight edge embedding groove 4, the pressing rectangular block 12 is embedded in the bending pressure block embedding groove chamber 7. Furthermore, the zigzag downward protrusion 13 on the bottom surface of the pressing rectangular block 12 is pressed against the end of the straight edge 9 of the tower coil 8, so that the end of the horizontal straight edge 9 is bent and pressed against the zigzag bending support step 6, forming the right end bend 16 and the left end bend 17. In other words, the end bend of the straight edge 9 is formed by pressing the end of the straight edge 9 down with the pressing rectangular block 12, so that it is formed on the zigzag bending support step 6.

[0025] On the horizontal strip plate 11 of the bending and pressing down on the outside of the pressing rectangular block 12, there is an inverted U-shaped limiting fork 15 at the end of the straight edge. When the horizontal strip plate 11 of the bending and pressing down is pressed down into the slot of the straight edge embedding groove 4, the inverted U-shaped limiting fork 15 at the end of the straight edge is inserted into the end of the straight edge 9 of the tower coil 8. Since the straight edge 9 is a stack of multiple turns of electromagnetic wire, each electromagnetic wire has an insulation layer and is relatively smooth, it is easy for the turns of the coil to slip and become disordered when bending it. The limiting fork 15 prevents this phenomenon from occurring and also guides the bending deformation. A pressing limiting eave 14 is provided at the top of the pressing rectangular block 12. The pressing limiting eave 14 can effectively control the bending pressure, that is, achieve effective bending of the straight edge and avoid damage to the insulation layer of the electromagnetic wire caused by excessive pressure.

[0026] A bending method based on a fixture for integrally bending the straight edge of a tower-shaped coil includes a fixture base plate 1 and a tower-shaped coil 8. The tower-shaped coil 8 is integrally wound and formed. A straight edge 9 is provided on the tower-shaped coil 8. The straight edge 9 is a stack of multiple turns of electromagnetic wire with an insulating layer. A front upright plate 2 and a rear upright plate 3 are fixedly arranged parallel to each other on the fixture base plate 1. A straight edge embedding groove 4 is provided between the front upright plate 2 and the rear upright plate 3. A bottom support intermediate pad 5 is fixedly provided at the bottom of the straight edge embedding groove 4. A zigzag bending support platform is provided on both sides of the top surface of the bottom support intermediate pad 5. Step 6; A bending pressure block embedding groove chamber 7 is provided on both sides of the top surface of the front upright plate 2 and the top surface of the rear upright plate 3. A zigzag bending downward pressing surface 10 is provided on the bottom surface of the bending pressure block embedding groove chamber 7. A bending downward pressing horizontal strip plate 11 connected to the press is provided directly above the groove opening of the straight edge embedding groove 4. A downward pressing rectangular block 12 is provided at both ends of the bending downward pressing horizontal strip plate 11. A zigzag downward protrusion 13 is provided on the bottom surface of the downward pressing rectangular block 12. A downward pressing limiting eave 14 is provided at the top of the downward pressing rectangular block 12. The feature is the following steps;

[0027] Step 1: Place the straight edge 9 of the entire tower-shaped coil 8 into the straight edge embedding groove 4 set between the front side plate 2 and the rear side plate 3, and place the lower end of the straight edge 9 on the top surface of the bottom support middle pad 5. The front side plate 2 and the rear side plate 3 form a limit on the stack of straight edges 9 in the front and rear directions.

[0028] The second step involves controlling the bending and pressing horizontal strip plate 11 connected to the press to press down, so that the bending and pressing horizontal strip plate 11 enters the slot of the straight edge embedding groove 4. At the same time, the pressing rectangular block 12 is embedded in the bending pressing block embedding groove 7 set between the front side plate 2 and the rear side plate 3. The bending and pressing horizontal strip plate 11 continues to press down, and the zigzag downward protrusion 13 set on the bottom surface of the pressing rectangular block 12 presses against the end of the straight edge 9, so that it is deformed to form the right end bend 16 and the left end bend 17 respectively. The pressing rectangular block 12 is embedded in the bending pressing block embedding groove 7. The cooperation between the two forms the left and right limit of the bending and pressing horizontal strip plate 11 during the pressing process.

[0029] Third step: When the pressure limiting eaves 14 set at the top of the pressure rectangular block 12 on the bending and pressing horizontal strip plate 11 come into contact with the top surface of the front upright plate 2, the bending and pressing horizontal strip plate 11 stops pressing down and maintains the pressure unchanged for 10 minutes. The bending and pressing horizontal strip plate 11 between the two pressure rectangular blocks 12 forms the middle part limit of the two ends of the straight edge 9 during the bending process, so that the middle part of the straight edge 9 will not arch upward during the bending.

[0030] Step 4: Control the bending and pressing horizontal strip plate 11 connected to the press to rise, thereby completing the simultaneous bending of both ends of the straight edge 9 on one side of the tower coil 8. In order to overcome the springback at both ends of the straight edge after the pressure is removed, the pressing can be repeated 2-3 times.

[0031] Step 5: Remove the straight edge 9 of the tower coil 8 from the straight edge embedding groove 4. Then, put the other straight edge of the tower coil 8 into the straight edge embedding groove 4. Repeat steps 1 to 4 to complete the simultaneous bending of both ends of the other straight edge of the tower coil 8. A tower coil can be formed by bending both sides.

[0032] The maximum height of the zigzag downward protrusion 13 on the bottom surface of the pressing rectangular block 12 is two millimeters greater than the bending depth of the right end bend 16, in order to overcome the springback after the straight edge 9 is bent. The height of the pressing rectangular block 12 is obtained through theoretical calculation based on the dimensions of the tooling structure and the amount of coil bending. Based on the theoretical calculation, the zigzag downward protrusion 13 can be increased by 2 millimeters, which can effectively overcome the springback. This was obtained through on-site experiments and exploration.

[0033] A bending method based on a bending fixture for bending the end of a straight edge of a tower-shaped coil is characterized in that an inverted U-shaped limiting fork 15 for the end of the straight edge is connected to a bending pressing horizontal strip plate 11 on the outside of the pressing rectangular block 12. When the bending pressing horizontal strip plate 11 is pressed down into the slot of the straight edge embedding groove 4, the inverted U-shaped limiting fork 15 for the end of the straight edge is inserted into the end of the straight edge 9 of the tower-shaped coil 8 to form a guide for bending the end of the straight edge 9 as a whole and to prevent the straight edge from diverging during bending.

Claims

1. A bending method based on a bending fixture for integral bending of the straight edge end of a tower-shaped coil, comprising a fixture base plate (1) and a tower-shaped coil (8), wherein a straight edge (9) is provided on the tower-shaped coil (8), and a front side plate (2) and a rear side plate (3) are fixedly provided parallel to each other on the fixture base plate (1), wherein a straight edge embedding groove (4) is provided between the front side plate (2) and the rear side plate (3), and a bottom support intermediate pad (5) is fixedly provided at the bottom of the straight edge embedding groove (4), and a zigzag bending support step (6) is provided on both sides of the top surface of the bottom support intermediate pad (5); and a zigzag bending support step (6) is provided on the top surface of the front side plate (2). Both ends of the end face and both ends of the top face of the rear upright plate (3) are provided with bending pressure block embedding groove chambers (7). On the bottom end face of the bending pressure block embedding groove chamber (7), a zigzag bending downward pressing surface (10) is provided. Above the groove opening of the straight edge embedding groove (4), a bending downward pressing horizontal strip plate (11) connected to the press is provided. At both ends of the bending downward pressing horizontal strip plate (11), a downward pressing rectangular block (12) is provided. On the bottom surface of the downward pressing rectangular block (12), a zigzag downward protrusion (13) is provided. A downward pressing limiting eave (14) is provided at the top of the downward pressing rectangular block (12). The feature is that Steps ； Step 1: Place the straight edge (9) of the entire tower-shaped coil (8) into the straight edge embedding groove (4) set between the front side plate (2) and the rear side plate (3), and place the lower end of the straight edge (9) on the top surface of the bottom support middle pad (5). The second step is to control the bending and pressing horizontal strip plate (11) connected to the press to press down, so that the bending and pressing horizontal strip plate (11) enters the groove of the straight edge embedding groove (4). At the same time, the pressing rectangular block (12) is embedded in the bending pressing block embedding groove chamber (7) set between the front side plate (2) and the rear side plate (3). The bending and pressing horizontal strip plate (11) continues to press down, and the "Z"-shaped downward protrusion (13) set on the bottom surface of the pressing rectangular block (12) presses against the end of the straight edge (9), so that it is deformed to form the right end bend (16) and the left end bend (17) respectively. Step 3: When the pressure limiting eaves (14) set at the top of the pressure rectangular block (12) on the bending and pressing horizontal strip plate (11) come into contact with the top surface of the front upright plate (2), the bending and pressing horizontal strip plate (11) stops pressing and the pressure remains unchanged for 10 minutes. Step 4: Control the bending and pressing horizontal strip plate (11) connected to the press to rise, thereby completing the overall simultaneous bending of both ends of the straight side (9) on one side of the tower coil (8); Step 5: Take the straight edge (9) of the tower coil (8) out of the straight edge embedding groove (4), and then put the other straight edge of the tower coil (8) into the straight edge embedding groove (4). Repeat the steps from step 1 to step 4 to complete the simultaneous bending of both ends of the other straight edge of the tower coil (8).

2. The bending method based on the integral bending fixture of the straight edge end of a tower-shaped coil according to claim 1, characterized in that, The maximum height of the zigzag downward protrusion (13) set on the bottom surface of the pressing rectangular block (12) is two millimeters greater than the bending depth of the right end bend (16) in order to overcome the springback after the straight edge (9) end is bent.

3. A bending method based on a bend fixture for integrally bending the straight edge of a tower-shaped coil according to claim 1 or 2, characterized in that, On the bent and pressed horizontal strip plate (11) outside the pressed rectangular block (12), there is a U-shaped limiting fork (15) at the end of the straight edge. When the bent and pressed horizontal strip plate (11) is pressed down into the slot of the straight edge embedding groove (4), the U-shaped limiting fork (15) at the end of the straight edge is inserted into the end of the straight edge (9) of the tower coil (8) to form a guide when the end of the straight edge (9) is bent as a whole.

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