Flat copper wire hairpin forming device

Abstract

The application discloses a flat copper wire hairpin forming device, which comprises a bottom plate, a first driver, a second driver, a first side plate and a second side plate, and further comprises a two-dimensional forming mechanism and a three-dimensional forming mechanism, wherein the three-dimensional forming mechanism comprises a three-dimensional sliding assembly and a three-dimensional forming assembly, the three-dimensional forming assembly comprises a three-dimensional forming seat and a three-dimensional forming die, the upper end of the three-dimensional forming die is provided with an I-shaped structure, the lower end of the three-dimensional forming die is provided with a forming part, the three-dimensional forming seat is provided with an I-shaped structure matching part, the three-dimensional forming seat is connected with the output end of the second driver, the three-dimensional forming seat is further connected with the three-dimensional sliding assembly, the I-shaped structure matching part is matched with the I-shaped structure, and a guide assembly is arranged between the three-dimensional forming seat and the three-dimensional forming die. The application can improve the shape precision of the flat copper wire hairpin after forming and the consistency of the flat copper wire hairpin forming.

Description

Technical Field

[0001] This invention relates to the field of flat copper wire manufacturing technology, and specifically to a flat copper wire hairpin forming device. Background Technology

[0002] Currently, flat copper wire hairpin motors are leading the industry trend with their advantages: high slot fill factor, high efficiency, light weight, and lower cost. However, the forming process of flat copper wire hairpins is very complex. Existing flat copper wire hairpin forming devices include two-dimensional forming molds and three-dimensional forming molds. In most devices, the two-dimensional forming molds and three-dimensional forming molds are independent molds. In the flat copper wire forming process, the flat copper wire needs to be formed horizontally in two dimensions to obtain a hairpin with the required two-dimensional shape. After that, it is taken out and then placed into the three-dimensional mold to make the two-dimensional hairpin undergo plastic deformation again, finally obtaining a hairpin with the required three-dimensional shape. If the two-dimensional mold and the three-dimensional mold are designed and developed separately, it will not only increase the production cost, but also reduce the hairpin forming efficiency.

[0003] To address the aforementioned issues, existing technologies integrate two-dimensional and three-dimensional models in their design. However, during the hairpin forming process, the precision of the fit between the two-dimensional and three-dimensional molds is too low, resulting in the inability to guarantee the shape accuracy and consistency of the hairpin. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a flat copper wire hairpin forming device that can improve the shape accuracy of the formed flat copper wire hairpin and enable continuous production.

[0005] The technical solutions to the above technical problems are as follows: A flat copper wire hairpin forming device includes a base plate, a first driver, and a second driver. The base plate has a first side plate and a second side plate. The first driver is disposed at one end of the first side plate and the second side plate, and the second driver is disposed at the other end of the first side plate and the second side plate. The device also includes: A two-dimensional forming mechanism, which is driven by a first driver and moves laterally along the base plate; A three-dimensional forming mechanism is driven by a second driver and moves vertically along the first and second side plates; The three-dimensional molding mechanism includes a three-dimensional sliding component and a three-dimensional molding component. The three-dimensional molding component includes a three-dimensional molding base and a three-dimensional molding mold. The three-dimensional molding mold includes an upper mold and a lower mold. The upper mold has an I-beam structure, and the lower mold has a molding part. The three-dimensional molding base has an I-beam structure mating part. The three-dimensional molding base is connected to the output end of the second driver. The three-dimensional molding base is also connected to the three-dimensional sliding component. The I-beam structure mating part mates with the I-beam structure. A guide component is provided between the three-dimensional molding base and the three-dimensional molding mold. The guide component includes an upper cover, a guide post, a guide sleeve, and a lower cover. The guide sleeve is arranged in the inner hole of the upper mold. The guide post passes through the guide sleeve and is clearance-fitted with the guide sleeve. One end of the upper cover is inserted into one end of the guide post, and the other end of the upper cover is connected to the three-dimensional molding base. The lower cover is inserted into the other end of the guide post.

[0006] Furthermore, the three-dimensional sliding assembly includes a first slide rail, a first slide block, and a first slide plate. The first slide rail is arranged on a first side plate and a second side plate. The first slide block is slidably engaged with the first slide rail. The first slide plate is connected to the first slide block on the first side plate and the second side plate. The first slide plate is also connected to the three-dimensional molding base.

[0007] Furthermore, the two-dimensional forming mechanism includes a two-dimensional sliding component and a two-dimensional forming component. The two-dimensional sliding component includes a second slide rail, a second slide block, and a second slide plate. The second slide rail is arranged on the base plate, the second slide block slides in cooperation with the second slide rail, the second slide plate is connected to the second slide block, and the second slide plate is also connected to the two-dimensional forming component.

[0008] Furthermore, the two-dimensional molding component includes a drive plate and a two-dimensional molding mold. The drive plate is fixed on the second slide plate and is also connected to the output end of the first driver. The two-dimensional molding mold is connected to the drive plate.

[0009] Furthermore, the two-dimensional molding mold is provided with a two-dimensional molding groove and a two-dimensional molding cone, which cooperate with the molding part of the three-dimensional molding mold.

[0010] Furthermore, the first side plate and the second side plate are respectively provided with a first feeding component and a second feeding component for conveying flat copper wires, and the first feeding component and the second feeding component are arranged opposite to each other on the first side plate and the second side plate.

[0011] Furthermore, the base plate is also provided with a material picking assembly, which includes a lower support block and a material picking plate. The lower support block is fixed on the base plate and is also connected to the first side plate and the second side plate. The lower support block is located below the three-dimensional forming mechanism. The material picking plate is connected to the lower support block and is also connected to the first side plate and the second side plate. The material picking plate is provided with a conical surface, and a material picking hook is provided on the conical surface. The two-dimensional forming cone of the two-dimensional forming mold is provided with a cavity, which cooperates with the material picking hook.

[0012] The beneficial effects of this invention are as follows: This invention adopts a set of molds for the two-dimensional forming mechanism and the three-dimensional forming mechanism, realizing the convenience of two-dimensional and three-dimensional forming of flat copper wire and improving continuous production efficiency. At the same time, the three-dimensional forming base and the three-dimensional forming mold of the three-dimensional forming mechanism are set with guide components, which improves the matching accuracy of the two-dimensional forming mechanism and the three-dimensional forming mechanism, and improves the shape accuracy and consistency of hairpin forming. Furthermore, the three-dimensional forming base and the three-dimensional forming mold are separate structures, which effectively improves the wear resistance and service life of the mold and reduces the difficulty of replacing parts after accidental damage. Attached Figure Description

[0013] Figure 1 This is a perspective view of the flat copper wire hairpin forming device of the present invention; Figure 2 This is a right view of the flat copper wire hairpin forming device of the present invention; Figure 3 This is a cross-sectional view of the flat copper wire hairpin forming device of the present invention; Figure 4 for Figure 3 Enlarged view of section A in the middle; Figure 5 This is a partial perspective view of the flat copper wire hairpin forming device of the present invention; Figure 6 This is a perspective view of the three-dimensional forming component of the flat copper wire hairpin forming device of the present invention; Figure 7 This is a front view of the three-dimensional forming component of the flat copper wire hairpin forming device of the present invention; Figure 8 This is a perspective view of the material handling component of the flat copper wire hairpin forming device of the present invention; Figure 9 This is a perspective view of the two-dimensional forming mold of the flat copper wire hairpin forming device of the present invention.

[0014] The markings in the attached diagram are: base plate 1, first side plate 2, second side plate 3, first driver 4, first driver mounting plate 4-1, second driver 5, second driver mounting plate 5-1, 3D molding base 10, I-beam structure mating part 10-1, first shoulder 10-1a, second shoulder 10-1b, 3D molding mold 11, upper mold 11a, lower mold 11b, I-beam structure 11-1, first locking part 11-1a, second locking part 11-1b, molding part 11. -2, upper cover 20, guide post 21, guide sleeve 22, lower cover 23, first slide rail 30, first slide block 31, first slide plate 32, second slide rail 40, second slide block 41, second slide plate 42, drive plate 50, two-dimensional forming mold 51, two-dimensional forming groove 51-1, two-dimensional forming cone 51-2, cavity 51-3, first feeding component 60, second feeding component 61, lower support block 70, material picking plate 71, conical surface 71-1, material picking hook 71-2. Detailed Implementation

[0015] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0016] First, it should be noted that, in order to make the objectives and technical solutions of this invention clearer, the technical solutions of this invention will be described more clearly and completely below in conjunction with the accompanying drawings. Obviously, the terms "upper," "lower," "left," "right," "front," and "rear," etc., used in the description to indicate direction are merely further and clearer descriptions of the technical solutions of this invention based on the accompanying drawings, and do not represent all embodiments of this invention. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention. Therefore, the following detailed description of the embodiments of this invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention.

[0017] like Figures 1 to 9 As shown, a flat copper wire hairpin forming device includes a base plate 1, a first driver 4, and a second driver 5. The base plate 1 has a first side plate 2 and a second side plate 3. The first driver 4 is disposed at one end of the first side plate 2 and the second side plate 3, and the second driver 5 is disposed at the other end of the first side plate 2 and the second side plate 3. The device also includes: A two-dimensional forming mechanism is driven by a first driver 4 and moves laterally along the base plate 1. The three-dimensional forming mechanism is driven by the second driver 5 and moves vertically along the first side plate 2 and the second side plate 3; The three-dimensional molding mechanism includes a three-dimensional sliding component and a three-dimensional molding component. The three-dimensional molding assembly includes a three-dimensional molding base 10 and a three-dimensional molding mold 11. The three-dimensional molding mold 11 includes an upper mold 11a and a lower mold 11b. The upper mold 11a is provided with an I-beam structure 11-1, and the lower mold 11b is provided with a molding part 11-2. The three-dimensional molding base 10 is provided with an I-beam structure mating part 10-1. The three-dimensional molding base 10 is connected to the output end of the second driver 5. The three-dimensional molding base 10 is also connected to a three-dimensional sliding assembly. The I-beam structure mating part 10-1 mates with the I-beam structure 11-1. A guide assembly is provided between the three-dimensional molding base 10 and the three-dimensional molding mold 11. The guide assembly includes an upper sleeve 20, a guide post 21, a guide sleeve 22, and a lower sleeve 23. The guide sleeve 22 is arranged in the inner hole of the upper mold 11a. The guide post 21 passes through the guide sleeve 22 and is clearance-fitted with the guide sleeve 22. One end of the upper sleeve 20 is inserted into one end of the guide post 21, and the other end of the upper sleeve 20 is connected to the three-dimensional molding base 10. The lower sleeve 23 is inserted into the other end of the guide post 21.

[0018] Specifically, the first side plate 2 and the second side plate 3 are arranged opposite to each other on the base plate 1. The first side plate 2 and the second side plate 3 are in an "L" shape. The first driver 4 and the second driver 5 are motors. Of course, the first driver 4 and the second driver 5 can also be hydraulic cylinders or pneumatic cylinders. The first driver 4 pushes the two-dimensional forming mechanism to move laterally on the base plate 1. The second driver 5 pushes the three-dimensional forming mechanism to move downward (vertically) from the first side plate 2 and the second side plate 3. Finally, the flat copper wire is squeezed into a hairpin shape by the two-dimensional forming mechanism and the three-dimensional forming mechanism. The first driver 4 is installed at one end of the first side plate 2 and the second side plate 3 through the first driver mounting plate 4-1. The second driver 5 is installed at the other end of the first side plate 2 and the second side plate 3 through the second driver mounting plate 5-1.

[0019] Specifically, the I-beam structure 11-1 on the three-dimensional molding mold 11 includes a first locking part 11-1a and a second locking part 11-1b. The I-beam structure mating part 10-1 of the three-dimensional molding base 10 includes a first locking shoulder 10-1a and a second locking shoulder 10-1b. The first locking part 11-1a mates with the first locking shoulder 10-1a, and the second locking part 11-1b mates with the second locking shoulder 10-1b, connecting the three-dimensional molding mold 11 to the three-dimensional molding base 10. When the second driver 5 drives the three-dimensional molding base 10 to move downward, the three-dimensional molding base 10 moves downward along the three-dimensional sliding assembly, pushing the three-dimensional molding mold 11 downward simultaneously. When the three-dimensional molding mold 11 is in the initial position, the three-dimensional molding... Due to its own gravity, the lower mold 11b of the mold 11 is separated from the upper mold 11a. When the lower mold 11b comes into contact with the flat copper wire, the second driver 5 continuously applies downward pressure. The upper mold 11a is pushed down by the three-dimensional forming seat 10, so that the upper mold 11a is in close contact with the lower mold 11b. During the movement, the upper mold 11a moves vertically downward under the action of the guide post 21, thereby aligning the centers of the lower mold 11b and the upper mold 11a. This ultimately improves the accuracy of the lower mold 11b when it is engaged with the two-dimensional forming mechanism. The lower sleeve 23 prevents the upper mold 11a and the lower mold 11b from completely separating, and the upper sleeve 20 enhances the connection strength between the upper mold 11a and the three-dimensional forming seat 10.

[0020] The three-dimensional sliding assembly includes a first slide rail 30, a first slide block 31, and a first slide plate 32. The first slide rail 30 is arranged on the first side plate 2 and the second side plate 3. The first slide block 31 is slidably engaged with the first slide rail 30. The first slide plate 32 is connected to the first slide block 31 on the first side plate 2 and the second side plate 3. The first slide plate 32 is also connected to the three-dimensional molding base 10.

[0021] Specifically, there are four first slide rails 30 and two first slide plates 32. The four first slide rails 30 are fixed to the two ends of the first side plate 2 and the second side plate 3 respectively. The two first slide plates 32 are connected to the two ends of the three-dimensional molding base 10 respectively. Each first slide plate 32 is slidably engaged with the two first slide rails 30 located at the same end of the first side plate 2 and the second side plate 3. When the second driver 5 drives the three-dimensional molding base 10 to move downward, the three-dimensional molding base 10 drives the first slide plates 32 at both ends to move downward under the action of the four first slide rails 30. At the same time, the three-dimensional molding base 10 will also drive the three-dimensional molding mold 11 to move downward.

[0022] The two-dimensional forming mechanism includes a two-dimensional sliding component and a two-dimensional forming component. The two-dimensional sliding component includes a second slide rail 40, a second slide block 41, and a second slide plate 42. The second slide rail 40 is arranged on the base plate 1. The second slide block 41 is slidably engaged with the second slide rail 40. The second slide plate 42 is connected to the second slide block 41 and is also connected to the two-dimensional forming component.

[0023] The two-dimensional molding assembly includes a drive plate 50 and a two-dimensional molding mold 51. The drive plate 50 is fixed on the second slide plate 42 and is also connected to the output end of the first driver 4. The two-dimensional molding mold 51 is connected to the drive plate 50.

[0024] Specifically, there are two second slide rails 40, which are arranged parallel to each other on the base plate 1. The first driver 4 pushes the drive plate 50 laterally, so that the drive plate 50 moves to the left or right along the two second slide rails 40 on the base plate 1 under the action of the second slide block 41, thereby allowing the drive plate 50 to drive the two-dimensional molding mold 51 to move to the left or right.

[0025] The two-dimensional molding mold 51 is provided with a two-dimensional molding groove 51-1 and a two-dimensional molding cone 51-2, which are in cooperation with the molding part 11-2 of the three-dimensional molding mold 11.

[0026] The first side plate 2 and the second side plate 3 are respectively provided with a first feeding component 60 and a second feeding component 61 for conveying flat copper wires. The first feeding component 60 and the second feeding component 61 are arranged opposite to each other on the first side plate 2 and the second side plate 3.

[0027] Specifically, before the flat copper wire is formed, the first feeding component 60 and the second feeding component 61 first feed the flat copper wire to the first side plate 2 and the second side plate 3, so that the flat copper wire is suspended in the first side plate 2 and the second side plate 3. Then, the first driver 4 is activated, and the first driver 4 pushes the two-dimensional forming mold 51 to move laterally, so that the two-dimensional forming cone 51-2 of the two-dimensional forming mold 51 contacts the flat copper wire. The two-dimensional forming mold 51 is continuously pushed, so that the flat copper wire is bent by the two-dimensional forming cone 51-2 and inserted into the two-dimensional forming groove 51-1 of the two-dimensional forming mold 51. At the same time, the second driver 5 will also push the three-dimensional forming mold 11 to move downward. Using the forming part 11-2 of the three-dimensional forming mold 11 and the two-dimensional forming groove 51-1 and the two-dimensional forming cone 51-2 of the two-dimensional forming mold 51, the straight flat copper wire is finally extruded and formed.

[0028] The base plate 1 is also provided with a material picking assembly, which includes a lower support block 70 and a material picking plate 71. The lower support block 70 is fixed on the base plate 1 and is also connected to the first side plate 2 and the second side plate 3. The lower support block 70 is located below the three-dimensional forming mechanism. The material picking plate 71 is connected to the lower support block 70 and is also connected to the first side plate 2 and the second side plate 3. The material picking plate 71 is provided with a conical surface 71-1 and a material picking hook 71-2. The two-dimensional forming cone 51-2 of the two-dimensional forming mold 51 is provided with a cavity 51-3, which cooperates with the material picking hook 71-2.

[0029] Specifically, when the first driver 4 pushes the two-dimensional forming mold 51 to move laterally, when the two-dimensional forming mold 51 moves to the limit position, the two-dimensional forming cone 51-2 of the two-dimensional forming mold 51 will contact the conical surface 71-1 of the material taking plate 71 (at this time, it indicates that the flat copper wire hair clip has been formed). Furthermore, the material taking hook 71-2 on the conical surface 71-1 will extend into the cavity 51-3 on the two-dimensional forming cone 51-2. When the first driver 4 drives the two-dimensional forming mold 51 to return from the limit position to the initial position, the two-dimensional forming mold 51 retracts to the right, the material taking hook 71-2 exits the cavity 51-3, and the formed flat copper wire hair clip falls onto the material taking hook 71-2. The material taking hook 71-2 makes it easier to take out the formed flat copper wire hair clip. In this way, continuous production of flat copper wire hair clips is realized.

[0030] Finally, it should be noted that the above-described embodiments are merely preferred embodiments of the present invention used to illustrate the technical solutions of the present invention, and are not intended to limit them, much less limit the scope of protection of the present invention; although the invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to depart from the scope of protection of the claims.

Claims

1. A flat copper wire hairpin forming device, comprising a base plate (1), a first driver (4), and a second driver (5), wherein the base plate (1) is provided with a first side plate (2) and a second side plate (3), the first driver (4) is disposed at one end of the first side plate (2) and the second side plate (3), and the second driver (5) is disposed at the other end of the first side plate (2) and the second side plate (3), characterized in that, Also includes: A two-dimensional forming mechanism is driven by a first driver (4) and moves laterally along a base plate (1). The two-dimensional forming mechanism includes a two-dimensional sliding component and a two-dimensional forming component. The two-dimensional sliding component includes a second slide rail (40), a second slide block (41), and a second slide plate (42). The second slide rail (40) is arranged on the base plate (1). The second slide block (41) is slidably engaged with the second slide rail (40). The second slide plate (42) is connected to the second slide block (41) and is also connected to the two-dimensional forming component. The two-dimensional forming component includes a drive plate (50) and a two-dimensional forming mold (51). The drive plate (50) is fixed on the second slide plate (42). The drive plate (50) is also connected to the output end of the first driver (4). The two-dimensional forming mold (51) is connected to the drive plate (50). The three-dimensional forming mechanism is driven by the second driver (5) and moves vertically along the first side plate (2) and the second side plate (3); The three-dimensional molding mechanism includes a three-dimensional sliding component and a three-dimensional molding component. The three-dimensional molding component includes a three-dimensional molding base (10) and a three-dimensional molding mold (11). The three-dimensional molding mold (11) includes an upper mold (11a) and a lower mold (11b). The upper mold (11a) is provided with an I-beam structure (11-1), and the lower mold (11b) is provided with a molding part (11-2). The three-dimensional molding base (10) is provided with an I-beam structure mating part (10-1). The three-dimensional molding base (10) is connected to the output end of the second driver (5). The three-dimensional molding base (10) is also connected to the three-dimensional sliding component. The I-beam structure mating part (10-1) mates with the I-beam structure (11-1). A guide component is provided between the three-dimensional molding base (10) and the three-dimensional molding mold (11). The guide component includes an upper cover (20), a guide post (21), a guide sleeve (22), and a lower cover (23). The guide sleeve (22) is arranged in the inner hole of the upper mold (11a), the guide post (21) passes through the guide sleeve (22) and is clearance-fitted with the guide sleeve (22), one end of the upper cover (20) is inserted into one end of the guide post (21), the other end of the upper cover (20) is connected to the three-dimensional molding seat (10), and the lower cover (23) is inserted into the other end of the guide post (21). The three-dimensional sliding assembly includes a first slide rail (30), a first slide block (31), and a first slide plate (32). The first slide rail (30) is arranged on the first side plate (2) and the second side plate (3). The first slide block (31) is slidably fitted with the first slide rail (30). The first slide plate (32) is connected to the first slide block (31) on the first side plate (2) and the second side plate (3). The first slide plate (32) is also connected to the three-dimensional molding seat (10).

2. The flat copper wire hair clip forming device according to claim 1, characterized in that, The two-dimensional molding mold (51) is provided with a two-dimensional molding groove (51-1) and a two-dimensional molding cone (51-2), and the two-dimensional molding groove (51-1) and the two-dimensional molding cone (51-2) cooperate with the molding part (11-2) of the three-dimensional molding mold (11).

3. The flat copper wire hair clip forming device according to claim 1, characterized in that, The first side plate (2) and the second side plate (3) are respectively provided with a first feeding component (60) and a second feeding component (61) for conveying flat copper wires. The first feeding component (60) and the second feeding component (61) are arranged opposite to each other on the first side plate (2) and the second side plate (3).

4. The flat copper wire hair clip forming device according to claim 1, characterized in that, The base plate (1) is also provided with a material picking component, which includes a lower support block (70) and a material picking plate (71). The lower support block (70) is fixed on the base plate (1). The lower support block (70) is also connected to the first side plate (2) and the second side plate (3). The lower support block (70) is located below the three-dimensional forming mechanism. The material picking plate (71) is connected to the lower support block (70). The material picking plate (71) is also connected to the first side plate (2) and the second side plate (3). The material picking plate (71) is provided with a conical surface (71-1). The conical surface (71-1) is provided with a material picking hook (71-2). The two-dimensional forming cone (51-2) of the two-dimensional forming mold (51) is provided with a cavity (51-3). The cavity (51-3) cooperates with the material picking hook (71-2).

Images