Stator flat wire automatic forming equipment and forming method thereof

Abstract

The stator flat wire automatic forming equipment comprises a coil stock feeding and straightening mechanism, a paint removing mechanism is arranged on one side of the coil stock feeding and straightening mechanism, a wire feeding mechanism is arranged on the side, away from the coil stock feeding and straightening mechanism, of the paint removing mechanism, and a cutting assembly is arranged on the wire feeding mechanism; a 2D forming mechanism is arranged on the side, away from the paint removing mechanism, of the wire feeding mechanism, a 3D forming mechanism is arranged on the side, away from the wire feeding mechanism, of the 2D forming mechanism, a detection assembly is arranged on the 3D forming mechanism, and a discharging storage assembly is arranged on the side, located on the detection assembly, of the 3D forming mechanism. The flat wire automatic forming equipment has the beneficial effects that the flat wire automatic forming equipment is ingenious in structural design, high in practicability and stable in operation, by applying the forming equipment and the flat wire forming method, the flat wire forming efficiency is effectively improved, the flat wire forming precision is also improved, and the production cost of the flat wire is further reduced.

Description

Technical Field

[0001] The invention relates to the technical field of flat wire forming, in particular to an automatic forming device for flat wires used in stators and a forming method thereof. Background Art

[0002] Taking the motor of new energy vehicles as an example, the motor stator using flat wire as winding has a high copper full rate, which can improve the power density of the motor; At present, in the field of new energy vehicles, stators with flat wire windings have become a development trend and have obvious advantages. For example, the slot full rate of flat wire windings reaches more than 70%, which can improve the efficiency of the motor; For another example, the flat wire conductor arranged in the stator slot has a small turn-to-turn contact area, and the probability of inter-turn or inter-phase insulation failure is low, which can significantly increase the voltage range of the motor. For another example, the flat wire conductor can directly transfer heat to the iron core or other cooling media, and has a strong heat dissipation capacity.

[0003] Flat wire is used in hairpin-type flat wire stator winding. During the production process of stator flat wire, it is necessary to form the flat wire. The flat wire forming operation requires the help of forming equipment. The existing forming equipment has a complex structure, inconvenient operation, and low operating efficiency, which leads to high production cost of the flat wire and poor forming accuracy, and cannot meet the production efficiency requirements of the flat wire. Therefore, an automatic forming equipment and forming method for stator flat wire are designed. Summary of the invention

[0004] The purpose of the present invention is to solve the above problems and to design an automatic forming device and a forming method for stator flat wire.

[0005] To achieve the above-mentioned purpose, the technical solution of the present invention is a kind of automatic forming equipment of flat wire for stator and its forming method, including a coil feeding and straightening mechanism, a paint removal mechanism is arranged on one side of the coil feeding and straightening mechanism, a wire feeding mechanism is arranged on the side of the paint removal mechanism away from the coil feeding and straightening mechanism, a cutting component is arranged on the wire feeding mechanism, a 2D forming mechanism is arranged on the side of the wire feeding mechanism away from the paint removal mechanism, a 3D forming mechanism is arranged on the side of the 2D forming mechanism away from the wire feeding mechanism, a detection component is arranged on the 3D forming mechanism, and a material unloading storage component is arranged on the 3D forming mechanism at one side of the detection component.

[0006] As a further description of the technical solution, the coil loading and straightening mechanism includes a first supporting frame, a coil storage device is provided on the first supporting frame, a flat wire tension adjustment assembly is provided on the first supporting frame, and a flat wire straightening assembly is provided on one side of the flat wire tension adjustment assembly on the first supporting frame.

[0007] As a further description of the present technical solution, the paint removal mechanism includes a second support frame arranged on one side of the coil feeding and straightening mechanism, the second support frame is provided with a flat wire length measuring encoder, and the second support frame is provided with a horizontal paint removal component and a vertical paint removal component.

[0008] As a further description of the present technical solution, the wire feeding mechanism includes a third support frame arranged on the side of the paint removal mechanism away from the coil feeding and straightening mechanism, a transverse conveying module is provided on the third support frame, a plurality of wire pulling assemblies are provided on the transverse conveying module, and a cutting assembly is provided on the third support frame.

[0009] As a further description of the technical solution, the cutting assembly includes a mounting frame arranged on the wire feeding mechanism, a flat wire cutting mold is arranged on one side of the bottom of the mounting frame, a cutting control power motor is arranged on the mounting frame, and the output end of the cutting control power motor is connected to the cutting mold through a connecting crank.

[0010] As a further description of the technical solution, the 2D forming mechanism includes a fourth support frame arranged on the side of the wire feeding mechanism away from the paint removal mechanism, the fourth support frame is provided with a top support assembly, the top support assembly is provided with a flat wire lateral moving module, the output end of the flat wire lateral moving module is provided with a flat wire transport reversing assembly, the fourth support frame is provided with a flat wire transfer assembly, and the fourth support frame is provided with a plurality of flat wire 2D forming assemblies at one end of the flat wire transfer assembly.

[0011] As a further description of the technical solution, the 3D forming mechanism includes a fifth support frame arranged on the side of the 2D forming mechanism away from the wire feeding mechanism, the fifth support frame is provided with a flat wire 3D forming component, the fourth support frame and the fifth support frame are provided with an auxiliary conveying module, the auxiliary conveying module is provided with an auxiliary conveying clamp, the fifth support frame is provided with a detection component on one side of the flat wire 3D forming component, and the fifth support frame is provided with a material unloading storage component.

[0012] As a further description of the technical solution, the detection component includes a detection conductive brush arranged on the fifth support frame and located on one side of the flat wire 3D molding component.

[0013] As a further description of the technical solution, the unloading storage assembly includes a qualified product storage rack arranged on a fifth support frame, and a failed product storage box is arranged on the fifth support frame at one side of the qualified product storage rack.

[0014] The flat wire forming method using the above-mentioned stator flat wire automatic forming device comprises the following steps: Step 1: Flat wire coil pay-off and straightening operation; the flat wire coil is placed on the coil storage device, one end of the flat wire passes through the flat wire tension adjustment component, and then passes through the flat wire straightening component, the tension of the flat wire is adjusted during the conveying process by the flat wire tension adjustment component, the flat wire is straightened by the flat wire straightening component, and the straightened flat wire is conveyed to the paint removal mechanism; Step 2: Flat wire paint removal operation; the flat wire passes through the paint removal mechanism, and the length of the flat wire is measured by the flat wire length measuring encoder. When the flat wire passes through the horizontal paint removal component, the flat wire is horizontally paint-removed, and when the flat wire passes through the vertical paint removal component, the flat wire is vertically paint-removed; Step 3: Flat wire feeding and cutting operation; the wire pulling component pulls the flat wire and conveys it under the action of the horizontal conveying module. When it is conveyed to the cutting component, the cutting control power motor drives the cutting die to cut the flat wire. The cut flat wire is placed on the flat wire transfer component for temporary storage; Step 4: Flat wire 2D forming operation; the flat wire on the flat wire transfer assembly is transported to the flat wire 2D forming assembly through the flat wire transport reversing assembly for flat wire 2D forming operation; the flat wire after the flat wire 2D forming operation is clamped by the auxiliary transport clamp; Step 5: Flat wire 3D forming operation; the auxiliary transporting claw is transported to the flat wire 3D forming component through the auxiliary transporting module to perform the flat wire 3D forming operation; Step six: Flat wire inspection and unloading operation; the auxiliary handling claws clamp the flat wire after 3D forming operation, and transport it to the detection conductive brush through the auxiliary handling module. The detection conductive brush is positive, the auxiliary handling claws are negative, the detection state is conductive, the processed flat wire is unqualified, and the insulation skin is damaged. The unqualified flat wire products are transported and placed in the unqualified product storage box through the auxiliary handling module. The detection state is non-conductive, the processed flat wire is qualified, and the qualified flat wire products are transported and placed on the qualified product storage rack through the auxiliary handling module.

[0015] The beneficial effect is that the automatic flat wire forming equipment of the technical solution has an ingenious structural design, strong practicality, and stable operation. The use of this forming equipment and flat wire forming method effectively improves the efficiency of flat wire forming, improves the forming accuracy of the flat wire, and further reduces the production cost of the flat wire. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic diagram of the overall structure of the present invention; Figure 2 It is a schematic diagram of the installation structure of the cutting assembly of the present invention; Figure 3 It is a schematic diagram of the installation structure of the qualified product storage rack of the present invention; Figure 4 It is a schematic diagram of the installation structure of the flat wire tension adjustment assembly of the present invention; Figure 5 It is a schematic diagram of the installation structure of the paint removal mechanism of the present invention; Figure 6 It is a schematic diagram of the installation structure of the flat wire transfer assembly of the present invention.

[0017] In the figure, 1. coil material feeding and straightening mechanism; 2. paint removal mechanism; 3. wire feeding mechanism; 4. cutting assembly; 5. 2D forming mechanism; 6. 3D forming mechanism; 7. detection assembly; 8. material unloading and storage assembly; 9. first supporting frame; 10. coil material storage device; 11. flat wire tension adjustment assembly; 12. flat wire straightening assembly; 13. second supporting frame; 14. flat wire length measuring encoder; 15. horizontal paint removal assembly; 16. vertical paint removal assembly; 17. third supporting frame; 18. horizontal conveying module; 19. wire pulling Assembly; 20. Mounting frame; 21. Flat wire cutting mold; 22. Cutting control power motor; 23. Connecting crank; 24. Fourth support frame; 25. Top support assembly; 26. Flat wire lateral movement module; 27. Flat wire handling reversing assembly; 28. Flat wire transfer assembly; 29. ​​Flat wire 2D forming assembly; 30. Fifth support frame; 31. Flat wire 3D forming assembly; 32. Auxiliary handling module; 33. Auxiliary handling clamp; 34. Detection conductive brush; 35. Qualified product storage rack; 36. Unqualified product storage box. DETAILED DESCRIPTION

[0018] First of all, the design intention of the present invention is explained. During the production process of flat wires for stators, the flat wires need to be formed. The flat wire forming operation requires the aid of forming equipment. The existing forming equipment has a complex structure, is inconvenient to operate, and has low operating efficiency, which leads to high production costs of the flat wires and poor forming accuracy, and cannot meet the production efficiency requirements of the flat wires. Therefore, the present invention designs an automatic forming device for flat wires for stators and a forming method thereof.

[0019] The present invention will be described in detail below in conjunction with the accompanying drawings. Figure 1-Figure 6 As shown, an automatic forming device for flat wires for stators comprises a coil feeding and straightening mechanism 1, a paint removal mechanism 2 is arranged on one side of the coil feeding and straightening mechanism 1, a wire feeding mechanism 3 is arranged on the side of the paint removal mechanism 2 away from the coil feeding and straightening mechanism 1, a cutting component 4 is arranged on the wire feeding mechanism 3, a 2D forming mechanism 5 is arranged on the side of the wire feeding mechanism 3 away from the paint removal mechanism 2, a 3D forming mechanism 6 is arranged on the side of the 2D forming mechanism 5 away from the wire feeding mechanism 3, a detection component 7 is arranged on the 3D forming mechanism 6, and a material unloading storage component 8 is arranged on the 3D forming mechanism 6 at one side of the detection component 7.

[0020] As a further description of the present technical solution, the coil loading and straightening mechanism 1 includes a first supporting frame 9, a coil storage device 10 is provided on the first supporting frame 9, a flat wire tension adjustment component 11 is provided on the first supporting frame 9, and a flat wire straightening component 12 is provided on the first supporting frame 9 on one side of the flat wire tension adjustment component 11.

[0021] As a further description of the present technical solution, the paint removal mechanism 2 includes a second support frame 13 arranged on one side of the coil feeding and straightening mechanism 1, and a flat wire length measuring encoder 14 is arranged on the second support frame 13, and a horizontal paint removal component 15 and a vertical paint removal component 16 are arranged on the second support frame 13.

[0022] As a further description of the present technical solution, the wire feeding mechanism 3 includes a third support frame 17 arranged on the side of the paint removal mechanism 2 away from the coil feeding and straightening mechanism 1, and a transverse conveying module 18 is provided on the third support frame 17, and a plurality of wire pulling assemblies 19 are provided on the transverse conveying module 18, and a cutting assembly 4 is provided on the third support frame 17.

[0023] As a further description of the present technical solution, the cutting assembly 4 includes a mounting frame 20 arranged on the wire feeding mechanism 3, a flat wire cutting mold 21 is arranged on the bottom side of the mounting frame 20, and a cutting control power motor 22 is arranged on the mounting frame 20, and the output end of the cutting control power motor 22 is connected to the cutting mold through a connecting crank 23.

[0024] As a further description of the present technical solution, the 2D forming mechanism 5 includes a fourth support frame 24 arranged on the side of the wire feeding mechanism 3 away from the paint removal mechanism 2, and a top support assembly 25 is arranged on the fourth support frame 24, and a flat wire lateral moving module 26 is arranged on the top support assembly 25, and a flat wire transport reversing assembly 27 is arranged at the output end of the flat wire lateral moving module 26, and a flat wire transfer assembly 28 is arranged on the fourth support frame 24, and a plurality of flat wire 2D forming assemblies 29 are arranged on the fourth support frame 24 at one end of the flat wire transfer assembly 28.

[0025] As a further description of the present technical solution, the 3D molding mechanism 6 includes a fifth support frame 30 arranged on the side of the 2D molding mechanism 5 away from the wire feeding mechanism 3, and a flat wire 3D molding component 31 is arranged on the fifth support frame 30, and an auxiliary transport module 32 is arranged on the fourth support frame 24 and the fifth support frame 30, and an auxiliary transport clamp 33 is arranged on the auxiliary transport module 32. A detection component 7 is arranged on the fifth support frame 30 on one side of the flat wire 3D molding component 31, and a material unloading storage component 8 is arranged on the fifth support frame 30.

[0026] As a further description of the present technical solution, the detection component 7 includes a detection conductive brush 34 arranged on the fifth support frame 30 and located on one side of the flat wire 3D molding component 31 .

[0027] As a further description of the present technical solution, the unloading storage assembly 8 includes a qualified product storage rack 35 arranged on the fifth support frame 30, and a defective product storage box 36 is arranged on the fifth support frame 30 at one side of the qualified product storage rack 35.

[0028] The specific structure of the present invention is described in detail above. The flat wire forming method of the stator flat wire automatic forming device using the technical solution will be described below, including the following steps: Step 1: pay-off and straightening of the flat wire coil; place the flat wire coil on the coil storage device 10, pass one end of the flat wire through the flat wire tension adjustment component 11, and then pass through the flat wire straightening component 12, adjust the tension of the flat wire during transportation through the flat wire tension adjustment component 11, straighten the flat wire through the flat wire straightening component 12, and transport the straightened flat wire to the paint removal mechanism 2; Step 2: Flat wire paint removal operation; the flat wire passes through the paint removal mechanism 2, and the length of the flat wire is measured by the flat wire length measurement encoder 14. When the flat wire passes through the horizontal paint removal component 15, the flat wire is horizontally paint-removed, and when the flat wire passes through the vertical paint removal component 16, the flat wire is vertically paint-removed; Step 3: Flat wire feeding and cutting operation; the wire pulling assembly 19 pulls the flat wire and conveys it under the action of the horizontal conveying module 18. When it is conveyed to the cutting assembly 4, the cutting control power motor 22 drives the cutting die to cut the flat wire. The cut flat wire is placed on the flat wire transfer assembly 28 for temporary storage; Step 4: Flat wire 2D forming operation; the flat wire on the flat wire transfer assembly 28 is transported to the flat wire 2D forming assembly 29 through the flat wire transport reversing assembly 27 for flat wire 2D forming operation; the flat wire after the flat wire 2D forming operation is clamped by the auxiliary transport clamp 33; Step 5: Flat wire 3D forming operation; the auxiliary transport clamp 33 is transported to the flat wire 3D forming assembly 31 through the auxiliary transport module 32 for flat wire 3D forming operation; Step six: Flat wire inspection and unloading operation; the auxiliary transport clamp 33 clamps the flat wire after the 3D forming operation, and transports it to the detection conductive brush 34 through the auxiliary transport module 32. The detection conductive brush 34 is the positive pole, and the auxiliary transport clamp 33 is the negative pole. The detection state is the conductive state. The processed flat wire is unqualified and the insulation skin is damaged. The unqualified flat wire product is transported and placed in the unqualified product storage box 36 through the auxiliary transport module 32. The detection state is the non-conductive state. The processed flat wire is qualified. The qualified flat wire product is transported and placed on the qualified product storage rack 35 through the auxiliary transport module 32.

[0029] The flat wire automatic forming equipment of the present technical solution has an ingenious structural design, strong practicality, and stable operation. The use of this forming equipment and the flat wire forming method effectively improves the efficiency of flat wire forming, improves the forming accuracy of the flat wire, and further reduces the production cost of the flat wire.

[0030] The above technical solutions only reflect the preferred technical solutions of the technical solutions of the present invention. Some changes that may be made to certain parts thereof by technicians in this technical field all reflect the principles of the present invention and fall within the protection scope of the present invention.

Claims

1. An automatic forming device for stator flat wire, characterized in that: The invention comprises a coil material feeding and straightening mechanism (1), a paint removal mechanism (2) is arranged on one side of the coil material feeding and straightening mechanism (1), a wire feeding mechanism (3) is arranged on the side of the paint removal mechanism (2) away from the coil material feeding and straightening mechanism (1), a cutting component (4) is arranged on the wire feeding mechanism (3), a 2D forming mechanism (5) is arranged on the side of the wire feeding mechanism (3) away from the paint removal mechanism (2), a 3D forming mechanism (6) is arranged on the side of the 2D forming mechanism (5) away from the wire feeding mechanism (3), a detection component (7) is arranged on the 3D forming mechanism (6), and a material unloading storage component (8) is arranged on the 3D forming mechanism (6) at the side of the detection component (7).

2. The automatic forming equipment for stator flat wire according to claim 1, characterized in that: The coil material feeding and straightening mechanism (1) comprises a first supporting chassis (9), a coil material storage device (10) is arranged on the first supporting chassis (9), a flat wire tension adjustment component (11) is arranged on the first supporting chassis (9), and a flat wire straightening component (12) is arranged on the first supporting chassis (9) at one side of the flat wire tension adjustment component (11).

3. The automatic forming equipment for stator flat wire according to claim 1, characterized in that: The paint removal mechanism (2) comprises a second support frame (13) arranged on one side of the coil feeding and straightening mechanism (1), the second support frame (13) being provided with a flat wire length measuring encoder (14), and the second support frame (13) being provided with a transverse paint removal component (15) and a vertical paint removal component (16).

4. The automatic forming equipment for stator flat wire according to claim 1, characterized in that: The wire feeding mechanism (3) comprises a third support frame (17) arranged on the side of the paint removal mechanism (2) away from the coil feeding and straightening mechanism (1), a transverse conveying module (18) on the third support frame (17), a plurality of wire pulling components (19) arranged on the transverse conveying module (18), and a cutting component (4) arranged on the third support frame (17).

5. The automatic stator flat wire forming equipment according to claim 1, characterized in that: The cutting assembly (4) comprises a mounting frame (20) arranged on the wire feeding mechanism (3), a flat wire cutting die (21) being arranged on one side of the bottom of the mounting frame (20), a cutting control power motor (22) being arranged on the mounting frame (20), and an output end of the cutting control power motor (22) being connected to the cutting die via a connecting crank (23).

6. The automatic stator flat wire forming equipment according to claim 1, characterized in that: The 2D forming mechanism (5) comprises a fourth support frame (24) arranged on a side of the wire feeding mechanism (3) away from the paint removal mechanism (2); a top support assembly (25) is arranged on the fourth support frame (24); a flat wire transverse moving module (26) is arranged on the top support assembly (25); a flat wire transport reversing assembly (27) is arranged at the output end of the flat wire transverse moving module (26); a flat wire transfer assembly (28) is arranged on the fourth support frame (24); and a plurality of flat wire 2D forming assemblies (29) are arranged on the fourth support frame (24) at one end of the flat wire transfer assembly (28).

7. The automatic forming equipment for stator flat wire according to claim 6, characterized in that: The 3D forming mechanism (6) comprises a fifth support frame (30) arranged on a side of the 2D forming mechanism (5) away from the wire feeding mechanism (3); a flat wire 3D forming component (31) is arranged on the fifth support frame (30); an auxiliary transport module (32) is arranged on the fourth support frame (24) and the fifth support frame (30); an auxiliary transport clamp (33) is arranged on the auxiliary transport module (32); a detection component (7) is arranged on the fifth support frame (30) at one side of the flat wire 3D forming component (31); and a material unloading storage component (8) is arranged on the fifth support frame (30).

8. The automatic stator flat wire forming equipment according to claim 7, characterized in that: The detection component (7) comprises a detection conductive brush (34) arranged on a fifth support frame (30) and located on one side of the flat wire 3D forming component (31).

9. The automatic stator flat wire forming equipment according to claim 8, characterized in that: The material unloading storage assembly (8) comprises a qualified product storage rack (35) arranged on a fifth support frame (30), and a defective product storage box (36) is arranged on one side of the qualified product storage rack (35) on the fifth support frame (30).

10. A method for forming a flat wire using the automatic forming equipment for stator flat wire according to any one of claims 1 to 9, characterized in that: The following steps are involved: Step 1: straightening the flat wire coil; placing the flat wire coil on the coil storage device (10), passing one end of the flat wire through the flat wire tension adjustment component (11), and then passing through the flat wire straightening component (12); adjusting the tension of the flat wire during transportation by the flat wire tension adjustment component (11); straightening the flat wire by the flat wire straightening component (12); and conveying the straightened flat wire to the paint removal mechanism (2); Step 2: paint removal of the flat wire; the flat wire passes through the paint removal mechanism (2), and the length of the flat wire is measured by the flat wire length measuring encoder (14). When the flat wire passes through the horizontal paint removal component (15), the flat wire is paint removed horizontally, and when the flat wire passes through the vertical paint removal component (16), the flat wire is paint removed vertically; Step 3: Flat wire feeding and cutting operation; the flat wire is pulled by the wire pulling assembly (19) and transported under the action of the horizontal conveying module (18). When the flat wire is transported to the cutting assembly (4), the cutting control power motor (22) drives the cutting die to cut the flat wire. The cut flat wire is placed on the flat wire transfer assembly (28) for temporary storage. Step 4: Flat wire 2D forming operation; the flat wire on the flat wire transfer assembly (28) is transported to the flat wire 2D forming assembly (29) by the flat wire transport reversing assembly (27) for flat wire 2D forming operation; the flat wire after the flat wire 2D forming operation is clamped by the auxiliary transport clamp (33); Step 5: Flat wire 3D forming operation; the auxiliary transport clamp (33) is transported to the flat wire 3D forming assembly (31) through the auxiliary transport module (32) to perform the flat wire 3D forming operation; Step 6: Flat wire inspection and unloading operation; the auxiliary handling clamp (33) clamps the flat wire after the 3D forming operation and transports it to the inspection conductive brush (34) through the auxiliary handling module (32). The inspection conductive brush (34) is positive and the auxiliary handling clamp (33) is negative. The inspection state is the on state. The processed flat wire is unqualified and the insulation is damaged. The unqualified flat wire product is transported and placed in the unqualified product storage box (36) through the auxiliary handling module (32). The inspection state is the off state. The processed flat wire is qualified. The qualified flat wire product is transported and placed on the qualified product storage rack (35) through the auxiliary handling module (32).

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