Stator coil uniform winding method and winding device thereof

Abstract

The invention relates to the technical field of motor stator windings, and discloses a stator coil uniform winding method and a winding device thereof, and the method comprises the steps of material preparation, wire pre-stretching, wire correction, quality detection, equipment debugging, parameter setting, winding and painting treatment. Wherein the lead is pre-stretched in the lead pre-stretching stage, so that the situation that the compactness and the shape of the lead are affected due to the fact that the length of the lead is changed due to stress release and elastic force recovery after the lead is wound, and the performance of the winding is affected due to uneven winding is avoided; and meanwhile, through the wire winding device, the structure of a tensioning mechanism in the wire winding device is improved, so that the wire winding device can adapt to processing of the pre-stretched wire, and the situation that the wire is broken due to too large tension in the wire winding process and the winding work of the wire is affected is avoided.

Description

Technical Field

[0001] The invention relates to the technical field of motor stator windings, and in particular to a stator coil uniform winding method and a winding device thereof. Background Art

[0002] The stator is an important component in the motor. The rotation of the rotor is achieved through the electromagnetic induction transmission between the stator and the rotor. There are an even number of winding teeth on the stator for winding the wires required for electromagnetic induction. At present, the existing stator winding usually adopts a flying fork winding machine to directly wind the wires. During the winding process, in order to ensure the performance of the motor and avoid problems such as unstable intensity distribution of the magnetic field inside the motor that affect the normal use of the motor, it is necessary to ensure that the wire can be evenly wound on each winding tooth during winding. Therefore, the existing winding machines will be equipped with a tensioning mechanism to make the wire in a high tension state during winding to ensure consistent winding tightness and improve winding uniformity.

[0003] Since the wires are generally made of metal materials, such as copper wires, these materials often have stress inside and have a certain degree of elasticity. During the winding process of the winding machine, even if there is a tension controller to ensure that it is in a high tension state, the residual stress in the wire will still be gradually released after winding, and due to its own elasticity, elastic recovery will occur, eventually causing the length of the wound wire to change, thereby affecting the tightness and shape of the winding, causing unevenness and affecting the performance of the motor. Summary of the invention

[0004] The present invention provides a stator coil uniform winding method and a winding device thereof, which solves the problem in the related art that the length of the wire changes after winding due to residual stress and elastic force inside the wire, affecting the winding uniformity of the winding.

[0005] To achieve the above object, the present invention adopts a technical solution: a stator coil uniform winding method, comprising the following steps:

[0006] S1: Material preparation: Prepare wires with consistent diameter and good quality, and check the appearance of the wires to ensure that they are not damaged;

[0007] S2: Wire pre-stretching: Use a wire pre-stretching machine to pre-stretch the wire in S1;

[0008] S3: Wire correction: A wire straightener is used to apply pressure to the wire that has been pre-stretched in S2 to straighten and repair the shape of the wire;

[0009] S4: Quality inspection: Perform quality inspection on the wires that have been pre-stretched and straightened to ensure that they are qualified;

[0010] S5: Equipment debugging: Select the flying fork winding machine, make sure the winding machine has been correctly installed and debugged, then install the stator on the winding machine and clean the stator slots of the stator to remove dust and impurities, finally install the wire that has been processed and quality inspected in S4 on the winding machine, and adjust the tensioning mechanism of the winding machine to ensure that the tension of the pre-processed and corrected wire is neither loose nor tight;

[0011] S6: Parameter setting: according to the stator requirements, set the winding machine's winding speed, flying fork frequency, number of winding layers, number of wires per layer and other parameters;

[0012] S7: Winding: Start the winding machine, and the flying fork mechanism of the winding machine will feed the wire into the stator slot according to the set parameters until the predetermined number of layers and turns is reached, then stop winding and cut the wire; for multi-strand wires, use a crimping joint or welding method to connect the ends of each strand of wire to form a complete winding of one phase;

[0013] S8: Repeat step S7 to complete the winding of each phase;

[0014] S9: Painting: After the winding is completely cooled, the winding is subjected to insulation painting, and finally quality inspection is performed to complete the processing.

[0015] A winding device, used to complete steps S5 to S8, comprising a workbench with a control unit, on which a tensioning mechanism connected to the control unit, a flying fork winding mechanism and a stator fixing mechanism are sequentially arranged along the wire conveying direction;

[0016] The tensioning mechanism includes a mounting plate arranged on a workbench, on which a traction wheel, a tensioning wheel component and a passive wheel component are sequentially arranged along the wire conveying direction, and the traction wheel is connected to a driving mechanism for pulling the wire forward for conveying; the tensioning wheel component is slidably arranged on the mounting plate up and down, and an elastic element is detachably arranged between the tensioning wheel component and the mounting plate, and the elastic element is used to drive the buffer wheel component to put the wire in a tensioned state.

[0017] The present invention is further configured such that the driving mechanism includes a rotating shaft rotatably arranged on the mounting plate, one end of the rotating shaft is fixedly connected to a traction wheel; and also includes a driving motor arranged on the mounting plate, a clutch assembly is arranged between the driving motor and the rotating shaft, and the clutch assembly is connected to a control unit for switching the linkage and disconnection between the driving motor and the rotating shaft.

[0018] The present invention is further configured such that the tensioning wheel component includes a guide rail arranged between the traction wheel and the passive wheel component, a buffer wheel is slidably arranged on the guide rail via a slider, and the buffer wheel is rotatably connected to the slider via a connecting shaft; and also includes a mounting block arranged on the top of the guide rail, and the elastic element abuts between the mounting block and the slider.

[0019] The present invention is further configured such that the guide rail is composed of an overload section, a stable section and a relaxed section from top to bottom, and the mounting plate is provided with a first position sensor and a second position sensor located on the sides of the middle of the overload section and the relaxed section, respectively, and the first and second position sensors are electrically connected to the drive mechanism through a control unit; the slider is provided with a sensing element that cooperates with the position sensor; when the slider slides to the overload section, the sensing element triggers the first position sensor so that the control unit controls the clutch mechanism to disconnect the connection between the drive motor and the rotating shaft; when the slider slides to the relaxed section, the second position sensor is triggered so that the control unit controls the drive motor to stop; and it also includes a third position sensor arranged on one side of the middle of the stable section, and the third position sensor is used to control the resetting of the clutch mechanism and the rotation of the drive motor through the control unit.

[0020] The present invention is further configured such that the clutch assembly includes a clutch block A slidably arranged on a rotating shaft and a clutch block B fixedly arranged on an output shaft of a driving motor, and the side surfaces of the clutch block A and the clutch block B opposite to each other are provided with mutually engaging protrusions; an abutment spring is sleeved on the rotating shaft, one end of the abutment spring abuts against the clutch block A, and the other end abuts against the rotating shaft to drive the clutch block to slide toward the clutch block B; and also includes a shift rod swingably arranged on a mounting plate, one end of the shift rod is provided with a shift fork connected to the clutch block A, and the other end abuts against a telescopic cylinder installed on the mounting plate, and the telescopic cylinder is electrically connected to the first position sensor and the third position sensor through a control unit.

[0021] The present invention is further configured such that the passive wheel component includes a fixed shaft connected to the mounting plate, a one-way bearing is fixedly connected to the fixed shaft, a wheel disc is fixedly connected to the one-way bearing, a rubber ring is wrapped around the outer circumference of the wheel disc, and a plurality of wire grooves for placing wires are arranged on the outer circumference of the rubber ring, and the wire grooves are V-shaped.

[0022] The present invention is further configured such that a pair of connected extrusion plates are provided on the mounting plate, the pair of extrusion plates are respectively located on both sides of the rubber ring, the pair of extrusion plates protrude toward one side of the rubber ring to form an arcuate surface for extruding the rubber ring, and the arcuate surface is located at a position where the rubber ring contacts the wire.

[0023] The present invention is further configured such that a plurality of balls are rollingly arranged on the arc surface of the extrusion plate.

[0024] The present invention is further configured such that a plurality of annular grooves are provided on the circumferential surface of the traction wheel, and rubber is laid in the annular grooves.

[0025] In summary, the beneficial effects of the present invention are:

[0026] Compared with the prior art, the present application can eliminate the residual stress inside the wire and reduce the elasticity of the wire by pre-stretching the wire through a wire pre-stretching machine before winding the wire, thereby avoiding changes in the winding tightness and shape due to the internal stress and elasticity of the wire after winding the wire, thereby affecting the uniformity of the wire winding; and by straightening and repairing the shape of the wire through a wire straightening machine after pre-stretching, the straightness and flatness of the wire can be improved to ensure the quality of the wire.

[0027] At the same time, the present application improves the tensioning device of the winding machine and, through the setting of the tensioning wheel component, can ensure that the tension is stable during the winding process of the wire. While in a tensioned state, the wire can be pre-stocked; thereby, when the winding speed of the flying fork winding mechanism of the winding machine is instantly accelerated during the winding process, the wire in a tensioned state can be allowed to pass through the wire stocked by the tensioning wheel component to avoid the situation where the tension increases instantly and becomes tight or even breaks; it ensures that the pre-treated wire will not break during the winding process, affecting the winding of the winding, so that the equipment can be more suitable for winding by the above method. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 Schematic diagram of the steps of this embodiment.

[0029] Figure 2 It is the overall structural diagram of this embodiment.

[0030] Figure 3 It is a front view of the tensioning mechanism of this embodiment.

[0031] Figure 4 It is an enlarged view of the tensioning mechanism of this embodiment.

[0032] Figure 5 2 is a structural diagram of the driving mechanism of this embodiment.

[0033] Figure 6 It is a three-dimensional diagram of the passive wheel component of this embodiment.

[0034] Figure numerals: 1, workbench; 2, control unit; 3, tensioning mechanism; 31, mounting plate; 32, traction wheel; 33, tensioning wheel component; 331, guide rail; 3311, overload section; 3312, stabilizing section; 3313, relaxation section; 332, slider; 333, buffer wheel; 334, mounting block; 335, first position sensor; 336, second position sensor; 337, third position sensor; 338, induction member; 34, elastic element; 35, drive Mechanism; 351, rotating shaft; 352, driving motor; 353, clutch assembly; 3531, clutch block A; 3532, clutch block B; 3533, shift rod; 3534, shift fork; 3535, telescopic cylinder; 36, passive wheel component; 361, fixed shaft; 362, one-way bearing; 363, wheel disc; 364, rubber ring; 365, wire groove; 366, extrusion plate; 367, arc surface; 368, ball; 4, flying fork winding mechanism; 5, stator fixing mechanism. DETAILED DESCRIPTION

[0035] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of the present invention.

[0036] like Figure 1-6 As shown, this embodiment discloses a stator coil uniform winding method, comprising the following steps:

[0037] S1: Material preparation: Prepare wires of consistent diameter and good quality, and ensure that they are not damaged; the material can be made of copper material with good conductivity; in order to ensure that the wires are not damaged, you can choose a reputable supplier and require relevant quality certification documents, and before winding, check the appearance of the wires to ensure that there are no cracks, scratches or indentations on the surface of the wires.

[0038] S2: Wire pre-stretching: Use a high-precision wire pre-stretching machine to pre-stretch the wire in S1; ensure the stability and accuracy of the stretching process through high precision; at the same time, during the pre-stretching process, by adjusting the stretching parameters (such as stretching speed, stretching force, etc.), the diameter uniformity of the wire can be optimized to ensure the quality of the wire;

[0039] S3: Wire correction: A wire straightener is used to apply pressure to the wire that has been pre-stretched in S2 to straighten and repair the shape of the wire;

[0040] Through straightening, the quality indicators of the wire, such as straightness and flatness, are improved, thereby improving the overall quality of the wire. This helps the performance and stability of the wire in subsequent use; it helps to reduce the scrap rate caused by shape problems of the wire;

[0041] S4: Quality inspection: Perform quality inspection on the wires that have been pre-stretched and straightened to ensure that they are qualified;

[0042] S5: Equipment debugging: Select a flying fork winding machine, ensure that the winding machine has been correctly installed and debugged, then install the stator on the winding machine and clean the stator slots of the stator to remove dust and impurities, finally install the wire that has been processed and quality inspected in S4 on the winding machine, and adjust the tensioning mechanism of the winding machine to make the tension of the pre-treated and corrected wire moderate; by replacing the elastic element in the tensioning mechanism, different tensions can be provided for the wire to achieve a tension that is neither too loose nor too tight.

[0043] S6: Parameter setting: according to the stator requirements, set the winding machine's winding speed, flying fork frequency, number of winding layers, number of wires per layer and other parameters;

[0044] S7: Winding: Start the winding machine, and the flying fork mechanism of the winding machine will feed the wire into the stator slot according to the set parameters until the predetermined number of layers and turns is reached, then stop winding and cut the wire; for multi-strand wires, use a crimping joint or welding method to connect the ends of each strand of wire to form a complete winding of one phase;

[0045] S8: Repeat step S7 to complete the winding of each phase;

[0046] S9: Painting: After the winding is completely cooled, the winding is subjected to insulation painting, and finally quality inspection is performed to complete the processing.

[0047] During the above method, the present application can eliminate the residual stress inside the wire and reduce the elasticity of the wire by pre-stretching the wire through a wire pre-stretching machine before winding the wire, thereby avoiding changes in the winding tightness and shape due to the internal stress and elasticity of the wire after the wire is wound, affecting the uniformity of the wire winding; and by straightening and repairing the shape of the wire through a wire straightening machine after pre-stretching, the straightness and flatness of the wire can be improved to ensure the quality of the wire.

[0048] However, after the wire is pre-stretched by the pre-stretching machine, it is more likely to break due to excessive tension than conventional untreated wires; and in existing winding machines, the tension of the wire is controlled by a tension controller; and the principle of the tension controller is to detect the tension of the wire through a tension sensor and send a signal to the control unit, and then let the control unit control the current of the motor to achieve control of the motor speed to achieve speed adjustment of the traction wheel 32.

[0049] However, during the winding process of the winding machine, the path and winding of the wire are completed with the high-speed rotation of the flying fork winding mechanism 4. Among them, when the flying fork winding mechanism 4 completes the winding of one of the stator winding teeth, it will switch to the next winding tooth. In this process, the moving path of the wire will produce an instantaneous change, which will cause the wire to be subjected to an instantaneous pulling force, causing the tension to increase instantly. In the process from the tension sensor in the tension controller receiving the signal of increased tension to controlling the motor speed to increase to the corresponding speed, the motor needs a certain buffer time to increase the speed. It is impossible to adapt well to the situation of this instantaneous increase in tension, which can easily cause the wire to become taut and break in this process, affecting production.

[0050] In the present application, the above-mentioned problem is solved by improving the tensioning mechanism 3 of the winding machine.

[0051] like Figure 2 As shown, the winding device includes a workbench 1 with a control unit 2, and a tensioning mechanism 3, a flying fork winding mechanism 4 and a stator fixing mechanism 5 connected to the control unit 2 are sequentially arranged on the workbench 1 along the wire conveying direction; the tensioning mechanism 3 can convey the wire to the flying fork winding mechanism 4 and keep the tension of the wire stable; and the flying fork winding mechanism 4 can perform winding operations on the stator fixed on the stator fixing mechanism 5 to complete the winding of the stator winding; and the flying fork winding mechanism 4 and the stator fixing mechanism 5 are both prior arts, and are not the improvement points of the present application, so they are not elaborated in detail.

[0052] like Figure 3As shown, in the present application, the tensioning mechanism 3 includes a mounting plate 31 arranged on the workbench 1, and a traction wheel 32, a tensioning wheel component 33 and a passive wheel component 36 are sequentially arranged on the mounting plate 31 along the wire conveying direction, and the traction wheel 32 is connected to a driving mechanism 35, which can actively rotate during the winding process to convey the external wire forward to realize the wire feeding action; then the wire will be sent to the tensioning wheel component 33 after passing through the traction wheel 32, and the tensioning wheel component 33 includes a guide rail 331 fixedly arranged on the mounting plate 31, and a slider 332 is slidably arranged on the guide rail 331, and a buffer wheel 333 is rotatably connected to the slider 332 through a connecting shaft, and the guide rail 331 is A mounting block 334 is detachably provided on the top by bolts, and an elastic element 34 is abutted between the mounting block 334 and the slider 332, wherein the elastic element 34 is a spring. The wire passing through the traction wheel 32 will pass through the buffer wheel 333 and the passive wheel component 36 in sequence, wherein according to the material and stretching amount of the wire, the staff can disassemble the mounting block 334 before winding, and then replace the elastic element 34 to provide different tensions for the wire; and the buffer wheel 333 can slide up and down on the guide rail 331, so as to provide a certain telescopic range for the change of the wire length, and realize the reservation of the wire to avoid the wire being stretched and broken due to instantaneous pulling.

[0053] However, the length of the wire reserved in the tensioning wheel component 33 is always limited. If the flying fork winding mechanism 4 allows the wire to move along a longer path during the winding process and the wire used is longer, when the reserved section of the wire is used up, the wire will still be tightened. Therefore, the present application makes further improvements based on the above-mentioned solution.

[0054] In this embodiment, if Figure 4-5As shown, the driving mechanism 35 of the traction wheel 32 includes a rotating shaft 351 rotatably arranged on the mounting plate 31, one end of the rotating shaft 351 is fixedly connected to the traction wheel 32; it also includes a driving motor 352 arranged on the mounting plate 31, a clutch assembly 353 is arranged between the driving motor 352 and the rotating shaft 351, the clutch assembly 353 includes a clutch block A3531 slidably arranged on the rotating shaft 351 and a clutch block B3532 fixedly arranged on the output shaft of the driving motor 352, and the side opposite to the clutch block A3531 and the clutch block B3532 are both provided with mutually engaging protrusions; an abutting spring is sleeved on the rotating shaft 351, one end of the abutting spring abuts against the clutch block A3531, and the other end abuts against the rotating shaft 351 to drive the clutch block to slide toward the clutch block B3532; It also includes a shift rod 3533 swingably arranged on the mounting plate 31, wherein a shift fork 3534 connected to the clutch block A3531 is arranged at one end of the shift rod 3533, and the shift fork 3534 slides with the circumference of the clutch block A3531 to allow the clutch block to rotate relative to the shift fork 3534; and a telescopic cylinder 3535 mounted on the mounting plate 31 is abutted at the other end, and the telescopic cylinder 3535 can be used to control the swing of the shift rod 3533. When the output end of the telescopic cylinder 3535 is extended, the shift rod 3533 will drive the shift fork 3534 to drive the clutch block A3531 away from the clutch block B3532 on the output shaft of the drive motor 352, thereby disconnecting the linkage between the rotating shaft 351 and the drive motor 352, so that the traction wheel 32 connected to the rotating shaft 351 can rotate freely on the mounting plate 31.

[0055] At the same time Figure 3-4 As shown, the guide rail 331 is composed of an overload section 3311, a stable section 3312 and a relaxation section 3313 from top to bottom. The mounting plate 31 is provided with a first position sensor 335 and a second position sensor 336 located at the middle side of the overload section 3311 and the relaxation section 3313, respectively. The first and second position sensors are both electrically connected to the driving mechanism 35 through the control unit 2. The slider 332 is provided with a sensing element 338 that cooperates with the position sensor, wherein the first, second and third sensors are all proximity switches, and the sensing element 338 is a metal sheet.

[0056] When the wire is pulled and tightened, the length of the wire at the buffer wheel 333 will be reduced first, and then the buffer wheel 333 will overcome the elastic force of the elastic element 34 and drive the slider 332 to move upward along the guide rail 331. As the slider 332 slides to the overload section 3311, the metal sensor 338 on the slider 332 will trigger the first position sensor 335, and then the first position sensor 335 will send a signal to the control unit 2; then the control unit 2 will drive the telescopic cylinder 3535 to start, so that the output end of the telescopic cylinder 3535 is extended to control the lever 3 533 swings, thereby separating the clutch block A3531 from the clutch block B3532. At this time, the traction wheel 32 connected to the rotating shaft 351 can rotate freely because it loses the linkage with the motor, so that one end of the wire is in a free state, allowing the buffer wheel 333 to freely pull the wire at one end of the traction wheel 32 under the action of the elastic element 34, thereby eliminating the tension caused by the tightening of the wire, until the buffer wheel 333 is reset to the middle of the stable section 3312, allowing the clutch block A3531 to re-fit with the clutch block B3532 under the action of the abutment spring to achieve rotation.

[0057] Compared with the motor, the sensing speed of the telescopic cylinder 3535 is faster, and it can control the motor to be disconnected from the rotating shaft 351 in the first time, so as to eliminate the pulling force on the wire in time, avoiding breakage due to excessive tension; at the same time, when the rotating shaft 351 and the driving motor 352 are in a separated state, the motor is still in a stable rotation state. Therefore, when the slider 332 slides to the stable section 3312 of the guide rail 331 and triggers the third position sensor 337, as the convex blocks between the clutch block A 3531 and the clutch block B 3532 abut and engage, the traction wheel 32 can return to a stable working speed in the first time, avoiding excessive changes in the tension of the wire during the acceleration of the motor.

[0058] When the slider 332 slides to the slack section 3313, the second position sensor 336 is triggered to enable the control unit 2 to control the drive motor 352 to stop. At this time, the traction wheel 32 is braked by the motor so that its rotation speed drops rapidly, so that the flying fork winding mechanism 4 can quickly consume the reserved wire at the buffer wheel 333 to avoid the wire being too long and affecting the tension, until the slider 332 moves to the middle of the stable section 3312 of the guide rail 331, so that the drive motor 352 can resume its rotation speed and the output end of the telescopic cylinder 3535 can be reset, so that the wire is in a stable tension state.

[0059] In this embodiment, in order to ensure that the flying fork winding mechanism 4 can stably wind the wire and avoid the buffer wheel 333 pulling the wire at the flying fork winding mechanism 4 to cause the wire to retreat and affect the processing, the present application also makes corresponding improvements to the passive wheel component 36;

[0060] like Figure 6 As shown, the passive wheel component 36 includes a fixed shaft 361 connected to the mounting plate 31, and a one-way bearing 362 is fixedly connected to the fixed shaft 361, wherein the one-way bearing 362 is an existing bearing part, and therefore the structure is not described in detail; a wheel disc 363 is fixedly connected to the one-way bearing 362, and a rubber ring 364 is wrapped around the outer circumference of the wheel disc 363, and a plurality of wire grooves 365 for placing wires are arranged on the outer circumference of the rubber ring 364, and the wire grooves 365 are V-shaped; the rubber ring 364 can increase the friction between the wire and the passive wheel, thereby avoiding sliding friction between the wire and the wheel disc 363 that causes the wire to retreat;

[0061] In this embodiment, a pair of connected extrusion plates 366 are provided on the mounting plate 31, and the pair of extrusion plates 366 are respectively located on both sides of the rubber ring 364, and the pair of extrusion plates 366 protrude toward one side of the rubber ring 364 to form an arc surface 367 for extruding the rubber ring 364, and the arc surface 367 is located at the position where the rubber ring 364 contacts the wire; through the pair of extrusion plates 366, when the wheel disc 363 of the passive wheel component 36 reaches the arc surface 367, the rubber ring 364 will be compressed and deformed inwardly under the action of the extrusion plates 366 , so that the V-shaped wire groove 365 arranged on the side of the rubber ring 364 can be deformed to clamp and fix the wire in the groove, avoiding the wire backing from affecting the uniformity of the winding; and the arrangement of multiple wire grooves 365 can avoid the entanglement between multiple wires, which is conducive to the uniform winding of the wires; and a plurality of balls 368 are rollingly arranged on the arc surface 367 of the extrusion plate 366. The arrangement of the balls 368 can reduce the sliding friction between the rubber ring 364 and the extrusion plate 366, ensuring that the wheel 363 can smoothly drive the rubber ring 364 to rotate.

[0062] In this embodiment, a plurality of annular grooves are provided on the circumferential surface of the traction wheel 32, and rubber is laid in the annular grooves; the plurality of annular grooves can prevent the traction wheel 32 from entanglement between the wires during the wire feeding process; at the same time, the principle of determining a straight line by two points can be used to cooperate with the wire groove 365 of the passive wheel component 36 to ensure that the wires are always on the same straight line during the transportation process, and to avoid path deviation affecting the uniformity of subsequent winding of the wires; the role of the rubber can increase the friction between the wires and the traction wheel 32, avoid slipping between the wires and the traction wheel 32, and make the transportation of the wires more stable and accurate.

[0063] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the design concept of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for uniformly winding a stator coil, characterized in that: The steps include: S1: Material preparation: Prepare wires with consistent diameter and good quality, and check the appearance of the wires to ensure that they are not damaged; S2: Wire pre-stretching: Use a wire pre-stretching machine to pre-stretch the wire in S1; S3: Wire correction: A wire straightener is used to apply pressure to the wire that has been pre-stretched in S2 to straighten and repair the shape of the wire; S4: Quality inspection: Perform quality inspection on the wires that have been pre-stretched and straightened to ensure that they are qualified; S5: Equipment debugging: Select the flying fork winding machine, make sure the winding machine has been correctly installed and debugged, then install the stator on the winding machine and clean the stator slots of the stator to remove dust and impurities, finally install the wire that has been processed and quality inspected in S4 on the winding machine, and adjust the tensioning mechanism of the winding machine to ensure that the tension of the pre-processed and corrected wire is neither loose nor tight; S6: Parameter setting: according to the stator requirements, set the winding machine's winding speed, flying fork frequency, number of winding layers, number of wires per layer and other parameters; S7: Winding: Start the winding machine, and the flying fork mechanism of the winding machine will feed the wire into the stator slot according to the set parameters until the predetermined number of layers and turns is reached, then stop winding and cut the wire; for multi-strand wires, use a crimping joint or welding method to connect the ends of each strand of wire to form a complete winding of one phase; S8: Repeat step S7 to complete the winding of each phase; S9: Painting: After the winding is completely cooled, the winding is subjected to insulation painting, and finally quality inspection is performed to complete the processing.

2. A winding device for completing steps S5 to S8 in claim 1, characterized in that: It comprises a workbench (1) with a control unit (2), wherein a tensioning mechanism (3) connected to the control unit (2), a flying fork winding mechanism (4) and a stator fixing mechanism (5) are sequentially arranged on the workbench (1) along the wire conveying direction; The tensioning mechanism (3) comprises a mounting plate (31) arranged on a workbench (1); a traction wheel (32), a tensioning wheel component (33) and a passive wheel component (36) are arranged on the mounting plate (31) in sequence along the wire conveying direction; the traction wheel (32) is connected to a driving mechanism (35) for pulling the wire forward for conveying; the tensioning wheel component (33) is slidably arranged on the mounting plate (31) up and down and an elastic element (34) is detachably arranged between the mounting plate (31); the elastic element (34) is used to drive a buffer wheel (333) component to put the wire in a tensioned state.

3. A winding device according to claim 2, characterized in that: The driving mechanism (35) comprises a rotating shaft (351) rotatably arranged on the mounting plate (31), one end of the rotating shaft (351) being fixedly connected to a traction wheel (32); and further comprises a driving motor (352) arranged on the mounting plate (31), a clutch assembly (353) being arranged between the driving motor (352) and the rotating shaft (351), and the clutch assembly (353) being connected to a control unit (2) for switching the linkage and disconnection between the driving motor (352) and the rotating shaft (351).

4. A winding device according to claim 2, characterized in that: The tension wheel component (33) comprises a guide rail (331) arranged between the traction wheel (32) and the passive wheel component (36); a buffer wheel (333) is slidably arranged on the guide rail (331) via a slider (332); the buffer wheel (333) is rotatably connected to the slider (332) via a connecting shaft; and a mounting block (334) is also arranged on the top of the guide rail (331); the elastic element (34) is abutted between the mounting block (334) and the slider (332).

5. A winding device according to claim 4, characterized in that: The guide rail (331) is composed of an overload section (3311), a stabilization section (3312) and a relaxation section (3313) from top to bottom. The mounting plate (31) is provided with a first position sensor (335) and a second position sensor (336) located on the sides of the middle of the overload section (3311) and the relaxation section (3313), respectively. The first and second position sensors are both electrically connected to the drive mechanism (35) through the control unit (2). The slider (332) is provided with a sensing element (338) that cooperates with the position sensor. When the slider (332) slides to the overload section (3311), the sensing element (338) is moved. The response component (338) triggers the first position sensor (335) so that the control unit (2) controls the clutch mechanism to disconnect the connection between the drive motor (352) and the rotating shaft (351); when the slider (332) slides to the relaxation section (3313), the second position sensor (336) is triggered so that the control unit (2) controls the drive motor (352) to stop rotating; and the device also includes a third position sensor (337) arranged on one side of the middle part of the stable section (3312), and the third position sensor (337) is used to control the resetting of the clutch mechanism and the rotation of the drive motor (352) through the control unit (2).

6. A winding device according to claim 3, characterized in that: The clutch assembly (353) comprises a clutch block A (3531) slidably arranged on the rotating shaft (351) and a clutch block B (3532) fixedly arranged on the output shaft of the driving motor (352), and the clutch block A (3531) and the clutch block B (3532) are both provided with mutually engaging protrusions on the opposite side thereof; an abutting spring is sleeved on the rotating shaft (351), and one end of the abutting spring abuts against the clutch block A (3531), and the other end abuts against the rotating shaft (351) to prevent the clutch block A (3531) from being engaged with the rotating shaft (351). The clutch block is driven to slide toward the clutch block B (3532); and the clutch block also includes a shifting rod (3533) swingably arranged on the mounting plate (31); one end of the shifting rod (3533) is provided with a shifting fork (3534) connected to the clutch block A (3531); the other end of the shifting rod (3533) is abutted against a telescopic cylinder (3535) installed on the mounting plate (31); the telescopic cylinder (3535) is electrically connected to the first position sensor (335) and the third position sensor (337) through the control unit (2).

7. A winding device according to claim 2, characterized in that: The passive wheel component (36) comprises a fixed shaft (361) connected to the mounting plate (31); a one-way bearing (362) is fixedly connected to the fixed shaft (361); a wheel disc (363) is fixedly connected to the one-way bearing (362); a rubber ring (364) is wrapped around the outer circumference of the wheel disc (363); a plurality of wire grooves (365) for placing wires are arranged on the outer circumference of the rubber ring (364); and the wire grooves (365) are V-shaped.

8. A winding device according to claim 7, characterized in that: A pair of connected extrusion plates (366) are provided on the mounting plate (31), and the pair of extrusion plates (366) are respectively located on both sides of the rubber ring (364). The pair of extrusion plates (366) protrude toward one side of the rubber ring (364) to form an arc surface (367) for extruding the rubber ring (364), and the arc surface (367) is located at a position where the rubber ring (364) contacts the wire.

9. A winding device according to claim 8, characterized in that: A plurality of balls (368) are rollingly arranged on the arc surface (367) of the extrusion plate (366).

10. A winding device according to claim 3, characterized in that: The circumferential surface of the traction wheel (32) is provided with a plurality of annular grooves, and rubber is laid in the annular grooves.

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