Welding device and welding method for hairpin wire of flat wire motor stator

Abstract

The invention belongs to the technical field of flat wire motors, and particularly relates to a welding device and method for a hairpin wire of a flat wire motor stator, and the welding device comprises a laser welding unit, a stop block, a cutting mechanism and a motion adjusting unit; the cutting mechanism is used for cutting one side, close to the first side surface, of the top end of each hairpin wire butt joint to form a welding inclined surface; the motion adjusting unit is used for driving the flat wire motor stator and the stop block to move relative to each other so as to move the stop block to the outer side of a second side surface opposite to the first side surface of any hairpin wire butt joint; the focus of the laser welding unit is adjusted to the welding inclined plane of the hairpin line butt joint; the laser welding unit is used for carrying out laser welding on the welding inclined surfaces of the butt joints of the hairpin lines so as to weld the end parts of the two hairpin lines at the butt joints of the hairpin lines into a whole; and the stop block is used for stopping leaked light emitted from a gap between the end parts of the two hairpin lines at the butt joint of the hairpin lines.

Description

Technical Field

[0001] The invention belongs to the technical field of flat wire motors, and in particular relates to a welding device and a welding method for a hairpin wire of a stator of a flat wire motor. Background Art

[0002] The research and development and manufacturing of automotive electric drive assemblies are the core links for the automotive industry to achieve electrification. Among them, the flat wire motor stator, also known as the hairpin winding permanent magnet synchronous motor stator, is a key component of the electric drive assembly. The design, research and development and manufacturing of the flat wire motor stator are important guarantees for the automotive electric drive assembly to achieve high power density and compact design.

[0003] The current manufacturing process of flat wire motor stators mainly consists of hairpin wire forming, slotting, flaring and twisting, flattening, welding, coating, and painting. Hairpin wire welding mainly consists of two processes: TIG welding and laser welding. Compared with TIG welding, laser welding can effectively improve the welding efficiency and welding quality of flat wire motor stators. Currently, laser welding is usually used for hairpin wire welding in the industry. Before laser welding, the part of the hairpin wire to be welded needs to be fixed with a clamp or a tooling disk, and then the visual system is used to position it, and then the laser is used for one or more scanning welding.

[0004] In the existing hairpin wire laser welding process, the ends of each hairpin wire butt joint of the flat wire motor stator are usually cut flat, and then a laser welding device is used to emit laser along the axial direction of the flat wire motor stator to perform laser welding on the top surface of each hairpin wire butt joint, so as to weld the ends of the two hairpin wires at the hairpin wire butt joint into one. However, there is a gap between the ends of the two hairpin wires at the hairpin wire butt joint during welding, and the laser is emitted vertically to the top surface of the hairpin wire butt joint during the laser welding process, there is usually a risk of light leakage during the welding process, and it is difficult to set a protective plate for protection, which causes the leakage light emitted from the gap between the ends of the two hairpin wires to directly irradiate the lower copper wire, causing damage to the copper wire paint, and then failing to withstand the voltage during electrical testing of the motor, which may eventually cause the motor to be scrapped. Summary of the invention

[0005] In order to solve the defects of the above-mentioned prior art, the present invention provides a welding device and a welding method for the hairpin wire of the flat wire motor stator to solve the technical problem in the existing hairpin wire laser welding process, that is, there is a gap between the ends of the two hairpin wires at the hairpin wire butt joint during welding, and the laser is emitted vertically to the top surface of the hairpin wire butt joint during the laser welding process, which usually causes the risk of light leakage during the welding process, and it is difficult to set a protective plate for protection, which leads to the laser energy directly irradiating the lower copper wire, causing the copper wire paint to be damaged, and then the voltage resistance cannot be exceeded during the electrical measurement of the motor, which may eventually lead to the motor being scrapped.

[0006] In order to achieve the above object, the technical solution of the present invention is as follows:

[0007] A welding device for a hairpin wire of a flat wire motor stator, comprising a laser welding unit, a blocking block, a cutting mechanism and a motion adjustment unit;

[0008] The cutting mechanism is used to cut each hairpin wire butt joint of the flat wire motor stator on a first side surface in a tangential direction of the flat wire motor stator, so as to form a welding bevel on a side of the top end of each hairpin wire butt joint close to the first side surface;

[0009] The motion adjustment unit is used to drive the stator of the flat wire motor and the blocking block to move relative to each other, so as to move the blocking block to the outside of the second side surface opposite to the first side surface of any hairpin wire butt joint (that is, the side of the second side surface away from the first side surface); the motion adjustment unit is also used to adjust the focus of the laser welding unit to the welding inclined surface of the hairpin wire butt joint after the blocking block is moved to the outside of the second side surface of any hairpin wire butt joint;

[0010] The laser welding unit is used to perform laser welding on the welding bevel of the hairpin wire butt joint, so as to weld the ends of the two hairpin wires at the hairpin wire butt joint into one;

[0011] The blocking block is used to block the leakage light emitted from the gap between the ends of two hairpin wires at the hairpin wire butt joint when the laser welding unit performs laser welding on the hairpin wire butt joint.

[0012] The cutting mechanism is used to cut the first side surface of each hairpin wire butt joint of the flat wire motor stator in the tangential direction of the flat wire motor stator, so as to form a welding bevel on the side of the top end of each hairpin wire butt joint close to the first side surface, and then the motion adjustment unit is used to drive the flat wire motor stator and the blocking block to move relative to each other, so as to move the blocking block to the outside of the second side surface opposite to the first side surface of any hairpin wire butt joint, so that during the process of the laser welding unit performing laser welding on the welding bevel of any hairpin wire butt joint, the blocking block on the outside of the second side surface of the hairpin wire butt joint can block the hairpin wire butt joint from being moved at the hairpin wire butt joint. The light leakage emitted from the gap between the ends of the two hairpin wires can effectively prevent the light leakage emitted from the gap between the ends of the two hairpin wires from directly irradiating the lower copper wire, thereby solving the technical problem that in the existing hairpin wire laser welding process, there is a gap between the ends of the two hairpin wires at the hairpin wire butt joint during welding, and the laser welding process is to emit laser vertically to the top surface of the hairpin wire butt joint, which usually causes the risk of light leakage during the welding process, and it is difficult to set a protective plate for protection, which leads to the laser energy directly irradiating the lower copper wire, causing the copper wire paint to be damaged, and then the voltage resistance cannot be achieved during the electrical measurement of the motor, which may eventually lead to the motor being scrapped.

[0013] Furthermore, the blocking block is used to open a clamping groove on one side facing the second side surface, and the clamping groove is opened along the axial direction of the flat wire motor stator. The motion adjustment unit is used to drive the flat wire motor stator and the blocking block to move relative to each other, so as to move the blocking block to the outside of the second side surface of any hairpin wire butt joint, and insert the hairpin wire butt joint into the clamping groove to limit the gap distance between the ends of the two hairpin wires at the hairpin wire butt joint.

[0014] By providing a clamping groove on the side of the blocking block facing the second side surface, before the laser welding unit performs laser welding on the welding bevel of any hairpin wire butt joint, the hairpin wire butt joint can be inserted into the clamping groove to limit the gap distance between the ends of the two hairpin wires at the hairpin wire butt joint, thereby achieving the effect of controlling the welding gap between the ends of the two hairpin wires at the hairpin wire butt joint. On the one hand, it can ensure the welding quality of the hairpin wire butt joint, and on the other hand, it can also reduce the leakage light emitted from the gap between the ends of the two hairpin wires at the hairpin wire butt joint.

[0015] The bottom of the clamping groove is used to block light leakage emitted from the gap between the ends of two hairpin wires at the hairpin wire butt joint during the process of the laser welding unit performing laser welding on the hairpin wire butt joint.

[0016] Furthermore, the blocking block is provided with a plurality of the clamping grooves; each of the clamping grooves is arranged along the radial direction of the stator of the flat wire motor;

[0017] The motion adjustment unit is used to drive the flat wire motor stator and the blocking block to move relative to each other, so as to insert the multiple hairpin wire docking connectors arranged radially along the flat wire motor stator of any hairpin wire docking unit among the multiple hairpin wire docking units arranged circumferentially on the flat wire motor stator into different clamping grooves respectively.

[0018] Furthermore, the notch of the clamping groove is provided with a guiding inclined surface.

[0019] By arranging a guiding slope at the notch of the clamping groove, it is possible to avoid, during the process of inserting the hairpin wire butt joint into the clamping groove, the hairpin wire butt joint being damaged by collision, extrusion and cutting with the blocking block due to positioning errors and excessive gap between the ends of the two hairpin wires at the hairpin wire butt joint, and the insertion process of the hairpin wire butt joint into the clamping groove can be avoided.

[0020] Furthermore, the width of the clamping groove is equal to the sum of twice the end thickness of the hairpin wire and a preset gap value; the preset gap value ranges from 1.5 mm to 2 mm.

[0021] Furthermore, the chamfer angle of the guide slope ranges from 30 degrees to 60 degrees.

[0022] Preferably, the chamfer angle of the guide slope is 45 degrees.

[0023] Further, the motion adjustment unit includes a first motion mechanism, a second motion mechanism and an adjustment mechanism;

[0024] The first motion mechanism is used to clamp and position the flat wire motor stator, and the first motion mechanism is also used to drive the flat wire motor stator to rotate around its central axis to rotate any of the hairpin wire docking units to a welding station;

[0025] The output end of the second motion mechanism is fixedly connected to the blocking block, and the second motion mechanism is used to drive the blocking block to approach the welding end of the flat wire motor stator or to move away from the flat wire motor stator along the axial direction of the flat wire motor stator; the second motion mechanism is also used to drive the blocking block to reciprocate along the tangential straight line of the flat wire motor stator, so as to insert a plurality of hairpin wire butt joints arranged along the radial direction of the flat wire motor stator of any hairpin wire butt joint unit rotated to the welding station into different clamping grooves, or to pull out each hairpin wire butt joint from each clamping groove;

[0026] The adjusting mechanism is used to adjust the focus of the laser welding unit to the welding inclined surface of each hairpin wire butt joint of the hairpin wire butt joint unit located on the welding station.

[0027] According to the welding device for the hairpin wire of the stator of a flat wire motor provided by the present invention, the present invention also provides a welding method for the hairpin wire of the stator of a flat wire motor, the welding method comprising:

[0028] Using a cutting mechanism to cut the first side surface of each hairpin wire butt joint of the flat wire motor stator in the tangential direction of the flat wire motor stator, so as to form a welding bevel on one side of the top end of each hairpin wire butt joint close to the first side surface;

[0029] The motion adjustment unit is used to drive the stator of the flat wire motor and the blocking block to move relative to each other, so as to move the blocking block to the outside of the second side surface opposite to the first side surface of any hairpin wire butt joint that has not been welded; and the focus of the laser welding unit is adjusted to the welding inclined surface of the hairpin wire butt joint;

[0030] The laser welding unit is used to perform laser welding on the welding bevel of the hairpin wire butt joint to weld the ends of the two hairpin wires at the hairpin wire butt joint into one. After completing the welding of the hairpin wire butt joint, continue to weld other hairpin wire butt joints that have not yet been welded.

[0031] Further, the following steps are used to weld the hairpin wire butt joint:

[0032] Step 1: using the motion adjustment unit to drive the flat wire motor stator and the blocking block to move relative to each other, so as to insert a plurality of hairpin wire butt joints arranged along the radial direction of the flat wire motor stator of any hairpin wire butt joint unit that has not been welded among a plurality of hairpin wire butt joint units arranged along the circumferential direction on the flat wire motor stator into different clamping grooves on the blocking block respectively;

[0033] Step 2: using the motion adjustment unit to adjust the focus of the laser welding unit to the welding slope of any unwelded hairpin wire butt joint of the hairpin wire butt joint unit;

[0034] Step 3: Use the laser welding unit to perform laser welding on the welding bevel of the hairpin wire butt joint. After completing the welding of the hairpin wire butt joint, return to step 2; until all the hairpin wire butt joints of the hairpin wire butt joint unit are welded, check whether the welding of all the hairpin wire butt joints of the flat wire motor stator is completed. If not, proceed to step 4;

[0035] Step 4: Use the motion adjustment unit to drive the flat wire motor stator and the blocking block to move relative to each other, so as to pull out the welded hairpin wire butt joints from the clamping grooves on the blocking block, and then insert multiple hairpin wire butt joints of the next hairpin wire docking unit that have not yet been welded and are arranged radially along the flat wire motor stator into different clamping grooves on the blocking block, and then return to step 2.

[0036] Furthermore, the step 4 includes the following sub-steps:

[0037] S401: using the second motion mechanism of the motion adjustment unit to drive the blocking block to move tangentially along the stator of the flat wire motor, so as to extract the welded hairpin wire butt joints from the clamping grooves on the blocking block;

[0038] S402: using the second motion mechanism to drive the blocking block away from the flat wire motor stator along the axial direction of the flat wire motor stator, so that the blocking block moves to the outside of the welding end of the flat wire motor stator;

[0039] S403: using the first motion mechanism of the motion adjustment unit to drive the stator of the flat wire motor to rotate around its central axis, so as to rotate the next hairpin wire docking unit that has not been welded to the welding station;

[0040] S404: using the second motion mechanism to drive the blocking block along the axial direction of the flat wire motor stator to approach the welding end of the flat wire motor stator, so as to move the blocking block to the outside of the second side surface of each hairpin wire butt joint of the hairpin wire butt joint unit located at the welding station;

[0041] S405: Use the second motion mechanism to drive the blocking block to move tangentially along the stator of the flat wire motor, so as to insert the multiple hairpin wire docking joints arranged radially along the stator of the flat wire motor of the hairpin wire docking unit rotated to the welding station into different clamping grooves on the blocking block, and then return to step 2. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] In order to more clearly illustrate the technical solution of the present invention, the drawings required for use in the implementation mode will be briefly introduced below. Obviously, the drawings described below are only some implementation modes of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0043] Figure 1 is a structural schematic diagram of the hairpin wire butt joint before cutting in Example 1;

[0044] Figure 2is a schematic structural diagram of the hairpin wire butt joint after cutting in Example 1;

[0045] Figure 3 is a schematic structural diagram of the flat wire motor stator in Example 1;

[0046] Figure 4 This is a schematic diagram of the matching relationship between the blocking block and the hairpin wire joint in Example 1. Figure 1 ;

[0047] Figure 5 This is a schematic diagram of the matching relationship between the blocking block and the hairpin wire joint in Example 1. Figure 2 ;

[0048] Figure 6 is a schematic structural diagram of the blocking block in Example 1;

[0049] Among them, 1—flat wire motor stator, 2—blocking block, 3—second motion mechanism;

[0050] 11—welding end, 12—hairpin line docking unit;

[0051] 121—Hairpin cable butt joint;

[0052] 1211 —top surface, 1212 —first side surface, 1213 —second side surface, 1214 —welding bevel surface;

[0053] 21—clamping groove, 22—guiding inclined surface. DETAILED DESCRIPTION

[0054] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0055] like Figure 1 As shown, in the existing hairpin wire laser welding process, the ends of each hairpin wire butt joint 121 of the flat wire motor stator are usually cut flat, and then a laser welding device is used to emit laser along the axial direction of the flat wire motor stator to laser weld the top end surface 1211 of each hairpin wire butt joint 121, so as to weld the ends of the two hairpin wires at the hairpin wire butt joint 121 into one. However, there is a gap between the ends of the two hairpin wires at the hairpin wire butt joint 121 during welding, and the laser is emitted vertically to the top end surface 1211 of the hairpin wire butt joint 121 during the laser welding process, resulting in a risk of light leakage during the welding process, and it is difficult to set a protective plate for protection, which results in the leakage light emitted from the gap between the ends of the two hairpin wires directly irradiating the lower copper wire, causing damage to the copper wire paint, and then failing to withstand the voltage during electrical testing of the motor, which may eventually cause the motor to be scrapped.

[0056] Embodiment 1:

[0057] In order to solve the above problems, Figures 1 to 6 As shown, embodiment 1 provides a welding device for a hairpin wire of a flat wire motor stator, comprising a laser welding unit, a blocking block 2, a cutting mechanism (not shown in the figure) and a motion adjustment unit (not all shown in the figure);

[0058] The cutting mechanism is used to cut the first side surface 1212 of each hairpin wire butt joint 121 of the flat wire motor stator 1 in the tangential direction of the flat wire motor stator 1, so as to form a welding bevel 1214 on one side of the top end of each hairpin wire butt joint 121 close to the first side surface 1212;

[0059] The motion adjustment unit is used to drive the flat wire motor stator 1 and the blocking block 2 to move relative to each other, so as to move the blocking block 2 to the outside of the second side surface 1213 opposite to the first side surface 1212 of any hairpin wire butt joint 121 (that is, the side of the second side surface 1213 away from the first side surface 1212); the motion adjustment unit is also used to adjust the focus of the laser welding unit to the welding bevel 1214 of the hairpin wire butt joint 121 after the blocking block 2 is moved to the outside of the second side surface 1213 of any hairpin wire butt joint 121;

[0060] The laser welding unit is used to laser weld the welding bevel 1214 of the hairpin wire butt joint 121, so as to weld the ends of the two hairpin wires at the hairpin wire butt joint 121 into one;

[0061] The blocking block 2 is used to block the leakage light emitted from the gap between the ends of two hairpin wires at the hairpin wire butt joint 121 when the laser welding unit performs laser welding on the hairpin wire butt joint 121 .

[0062] The cutting mechanism is used to cut the first side surface 1212 of each hairpin wire butt joint 121 of the flat wire motor stator 1 in the tangential direction of the flat wire motor stator 1, so as to form a welding bevel 1214 on the side of the top end of each hairpin wire butt joint 121 close to the first side surface 1212, and then the motion adjustment unit is used to drive the flat wire motor stator 1 and the blocking block 2 to move relative to each other, so as to move the blocking block 2 to the outside of the second side surface 1213 opposite to the first side surface 1212 of any hairpin wire butt joint 121, so that during the process of laser welding of the welding bevel 1214 of any hairpin wire butt joint 121 by the laser welding unit, the blocking block 2 on the outside of the second side surface 1213 of the hairpin wire butt joint 121 can block the hairpin wire from moving from the hairpin wire butt joint 121. The light leakage emitted from the gap between the ends of the two hairpin wires at the hairpin wire butt joint 121 can effectively prevent the leakage light emitted from the gap between the ends of the two hairpin wires from directly irradiating the lower copper wire, thereby solving the technical problem in the existing hairpin wire laser welding process, that is, there is a gap between the ends of the two hairpin wires at the hairpin wire butt joint 121 during welding, and the laser is emitted vertically to the top surface 1211 of the hairpin wire butt joint 121 during the laser welding process, which usually causes the risk of light leakage during the welding process, and it is difficult to set a protective plate for protection, which leads to the laser energy directly irradiating the lower copper wire, causing the copper wire paint to be damaged, and then the voltage resistance cannot be achieved during the electrical measurement of the motor, which may eventually lead to the motor being scrapped.

[0063] In one embodiment, if Figures 4 to 6 As shown, the blocking block 2 is used to open a clamping groove 21 on one side facing the second side 1213, and the clamping groove 21 is opened along the axial direction of the flat wire motor stator 1. The motion adjustment unit is used to drive the flat wire motor stator 1 and the blocking block 2 to move relative to each other, so as to move the blocking block 2 to the outside of the second side 1213 of any hairpin wire docking joint 121, and insert the hairpin wire docking joint 121 into the clamping groove 21, so as to limit the gap distance between the ends of the two hairpin wires at the hairpin wire docking joint 121.

[0064] By providing a clamping groove 21 on the side of the blocking block 2 facing the second side surface 1213, before the laser welding unit performs laser welding on the welding bevel 1214 of any hairpin wire butt joint 121, the hairpin wire butt joint 121 can be inserted into the clamping groove 21 to limit the gap distance between the ends of the two hairpin wires at the hairpin wire butt joint 121, thereby achieving the effect of controlling the welding gap between the ends of the two hairpin wires at the hairpin wire butt joint 121. On the one hand, it can ensure the welding quality of the hairpin wire butt joint 121, and on the other hand, it can also reduce the leakage light emitted from the gap between the ends of the two hairpin wires at the hairpin wire butt joint 121.

[0065] The bottom of the clamping groove 21 is used to block the light leakage emitted from the gap between the ends of the two hairpin wires at the hairpin wire butt joint 121 during the laser welding of the hairpin wire butt joint 121 by the laser welding unit.

[0066] In one embodiment, if Figures 4 to 6 As shown, a plurality of clamping grooves 21 are formed on the blocking block 2; each clamping groove 21 is arranged along the radial direction of the flat wire motor stator 1;

[0067] The motion adjustment unit is used to drive the flat wire motor stator 1 and the blocking block 2 to move relative to each other, so as to insert the multiple hairpin wire docking joints 121 arranged radially along the flat wire motor stator 1 of any hairpin wire docking unit 12 among the multiple hairpin wire docking units 12 arranged circumferentially on the flat wire motor stator 1 into different clamping grooves 21 respectively.

[0068] The number of the clamping grooves 21 on the blocking block 2 is at least greater than the number of the hairpin wire docking joints 121 disposed along the radial direction of the flat wire motor stator 1 and included in the hairpin wire docking unit 12;

[0069] In the present embodiment 1, each hairpin wire docking unit 12 comprises three hairpin wire docking joints 121 arranged along the radial direction of the flat wire motor stator 1, and three clamping grooves 21 are correspondingly formed on the blocking block 2.

[0070] Preferably, in this embodiment 1, Figure 6 As shown, the notch of the clamping groove 21 is provided with a guiding inclined surface 22 .

[0071] By setting a guiding slope 22 at the notch of the clamping groove 21, it is possible to avoid the hairpin wire butt joint 121 from colliding, squeezing and cutting with the blocking block 2 due to positioning errors and excessive gap between the ends of the two hairpin wires at the hairpin wire butt joint 121, thereby damaging the hairpin wire butt joint. It can also make the insertion process of the hairpin wire butt joint 121 into the clamping groove 21 smoother.

[0072] Preferably, in the present embodiment 1, the width of the clamping groove 21 is equal to the sum of twice the end thickness of the hairpin wire and a preset gap value; the preset gap value ranges from 1.5 mm to 2 mm.

[0073] In one embodiment, the chamfer angle of the guide slope 22 ranges from 30 degrees to 60 degrees.

[0074] Preferably, in this embodiment 1, the chamfer of the guide slope 22 is 45 degrees.

[0075] In this embodiment 1, Figures 4 to 6As shown, the motion adjustment unit includes a first motion mechanism (not shown in the figure), a second motion mechanism 3 and an adjustment mechanism (not shown in the figure).

[0076] The first motion mechanism is used to clamp and position the flat wire motor stator 1, and the first motion mechanism is also used to drive the flat wire motor stator 1 to rotate around its central axis to rotate any hairpin wire docking unit 12 to the welding station;

[0077] The output end of the second motion mechanism 3 is fixedly connected to the blocking block 2, and the second motion mechanism 3 is used to drive the blocking block 2 to approach the welding end 11 of the flat wire motor stator 1 or to move away from the flat wire motor stator 1 along the axial direction of the flat wire motor stator 1; the second motion mechanism 3 is also used to drive the blocking block 2 to reciprocate along the tangential straight line of the flat wire motor stator 1, so as to insert a plurality of hairpin wire butt joints 121 arranged along the radial direction of the flat wire motor stator 1 of any hairpin wire butt joint unit 12 rotated to the welding station into different clamping grooves 21 respectively, or to extract each hairpin wire butt joint 121 from each clamping groove 21;

[0078] The adjustment mechanism is used to adjust the focus of the laser welding unit to the welding bevel 1214 of each hairpin wire butt joint 121 of the hairpin wire butt joint unit 12 located at the welding station.

[0079] Embodiment 2:

[0080] According to the welding device for the hairpin wire of the stator of a flat wire motor provided in Example 1, Example 2 provides a welding method for the hairpin wire of the stator of a flat wire motor, the welding method comprising:

[0081] The first side surface 1212 of each hairpin wire joint 121 of the flat wire motor stator 1 in the tangential direction of the flat wire motor stator 1 is cut by a cutting mechanism, so as to form a welding bevel 1214 on one side of the top end of each hairpin wire joint 121 close to the first side surface 1212;

[0082] The motion adjustment unit is used to drive the flat wire motor stator 1 and the blocking block 2 to move relative to each other, so as to move the blocking block 2 to the outside of the second side surface 1213 opposite to the first side surface 1212 of any hairpin wire butt joint 121 that has not been welded; and the focus of the laser welding unit is adjusted to the welding bevel 1214 of the hairpin wire butt joint 121;

[0083] The laser welding unit is used to perform laser welding on the welding bevel 1214 of the hairpin wire butt joint 121 to weld the ends of the two hairpin wires at the hairpin wire butt joint 121 into one. After completing the welding of the hairpin wire butt joint 121, continue to weld other hairpin wire butt joints 121 that have not yet been welded.

[0084] The following steps are used to weld the hairpin wire butt joint 121:

[0085] Step 1: using a motion adjustment unit to drive the flat wire motor stator 1 and the blocking block 2 to move relative to each other, so as to insert a plurality of hairpin wire docking joints 121 arranged along the radial direction of the flat wire motor stator 1 of any unwelded hairpin wire docking unit 12 among a plurality of hairpin wire docking units 12 arranged along the circumferential direction on the flat wire motor stator 1 into different clamping grooves 21 on the blocking block 2 respectively;

[0086] Step 2: Use the motion adjustment unit to adjust the focus of the laser welding unit to the welding bevel 1214 of any unwelded hairpin wire butt joint 121 of the hairpin wire butt joint unit 12;

[0087] Step 3: Use a laser welding unit to laser weld the welding bevel 1214 of the hairpin wire butt joint 121. After the welding of the hairpin wire butt joint 121 is completed, return to step 2; until the welding of all the hairpin wire butt joints 121 of the hairpin wire butt joint unit 12 is completed, check whether the welding of all the hairpin wire butt joints 121 of the flat wire motor stator 1 is completed. If not, go to step 4;

[0088] Step 4: Use the motion adjustment unit to drive the flat wire motor stator 1 and the blocking block 2 to move relative to each other, so as to pull out the welded hairpin wire butt joints 121 from the clamping grooves 21 on the blocking block 2, and then insert the multiple hairpin wire butt joints 121 of the next hairpin wire docking unit 12 that have not yet been welded and are arranged along the radial direction of the flat wire motor stator 1 into different clamping grooves 21 on the blocking block 2, and then return to step 2.

[0089] Wherein, the above step 4 includes the following sub-steps:

[0090] S401: Use the second motion mechanism 3 of the motion adjustment unit to drive the blocking block 2 to move tangentially along the stator 1 of the flat wire motor (specifically, Figure 4 Taking the direction in the figure as an example, that is, the second motion mechanism 3 of the motion adjustment unit drives the blocking block 2 to move rightward along the tangential direction of the flat wire motor stator 1), so as to extract the welded hairpin wire butt joints 121 from the clamping grooves 21 on the blocking block 2;

[0091] S402: using the second motion mechanism 3 to drive the blocking block 2 away from the flat wire motor stator 1 along the axial direction of the flat wire motor stator 1, so that the blocking block 2 moves to the outside of the welding end 11 of the flat wire motor stator 1;

[0092] S403: using the first motion mechanism of the motion adjustment unit to drive the flat wire motor stator 1 to rotate around its central axis, so as to rotate the next hairpin wire docking unit 12 that has not been welded to the welding station;

[0093] S404: using the second motion mechanism 3 to drive the blocking block 2 along the axial direction of the flat wire motor stator 1 to approach the welding end 11 of the flat wire motor stator 1, so as to move the blocking block 2 to the outside of the second side surface 1213 of each hairpin wire butt joint 121 of the hairpin wire butt joint unit 12 located at the welding station;

[0094] S405: Use the second motion mechanism 3 to drive the blocking block 2 to move tangentially along the stator 1 of the flat wire motor (specifically, Figure 4 Taking the direction in as an example, that is, using the second motion mechanism 3 of the motion adjustment unit to drive the blocking block 2 to move leftward along the tangential direction of the flat wire motor stator 1), a plurality of hairpin wire docking joints 121 arranged radially along the flat wire motor stator 1 of the hairpin wire docking unit 12 rotated to the welding station are respectively inserted into different clamping grooves 21 on the blocking block 2, and then return to step 2.

[0095] The welding device and welding method of the hairpin wire of the flat wire motor stator provided by the present invention have at least the following technical effects or advantages:

[0096] 1. Cut the first side surface 1212 of each hairpin wire butt joint 121 of the flat wire motor stator 1 in the tangential direction of the flat wire motor stator 1 by using a cutting mechanism, so as to form a welding bevel 1214 on the side of the top end of each hairpin wire butt joint 121 close to the first side surface 1212, and then use a motion adjustment unit to drive the flat wire motor stator 1 and the blocking block 2 to move relative to each other, so as to move the blocking block 2 to the outside of the second side surface 1213 opposite to the first side surface 1212 of any hairpin wire butt joint 121, so that in the process of laser welding of the welding bevel 1214 of any hairpin wire butt joint 121 by the laser welding unit, the blocking block 2 on the outside of the second side surface 1213 of the hairpin wire butt joint 121 can block the welding bevel 1214 from the hairpin wire butt joint 121. The light leakage emitted from the gap between the ends of the two hairpin wires at the hairpin wire butt joint 121 can effectively prevent the leakage light emitted from the gap between the ends of the two hairpin wires from directly irradiating the lower copper wire, thereby solving the technical problem in the existing hairpin wire laser welding process, that is, there is a gap between the ends of the two hairpin wires at the hairpin wire butt joint 121 during welding, and the laser is emitted vertically to the top surface 1211 of the hairpin wire butt joint 121 during the laser welding process, which usually causes the risk of light leakage during the welding process, and it is difficult to set a protective plate for protection, which leads to the laser energy directly irradiating the lower copper wire, causing the copper wire paint to be damaged, and then failing to withstand the voltage during electrical testing of the motor, which may eventually lead to the motor being scrapped.

[0097] 2. By providing a clamping groove 21 on the side of the blocking block 2 facing the second side surface 1213, before the laser welding unit performs laser welding on the welding bevel 1214 of any hairpin wire butt joint 121, the hairpin wire butt joint 121 can be inserted into the clamping groove 21 to limit the gap distance between the ends of the two hairpin wires at the hairpin wire butt joint 121, thereby achieving the effect of controlling the welding gap between the ends of the two hairpin wires at the hairpin wire butt joint 121. On the one hand, it can ensure the welding quality of the hairpin wire butt joint 121, and on the other hand, it can also reduce the leakage light emitted from the gap between the ends of the two hairpin wires at the hairpin wire butt joint 121.

[0098] 3. By setting a guiding slope 22 at the notch of the clamping groove 21, it is possible to avoid the hairpin wire butt joint 121 from colliding, squeezing and cutting with the blocking block 2 due to positioning errors and excessive gap between the ends of the two hairpin wires at the hairpin wire butt joint 121, thereby damaging the hairpin wire butt joint. It can also make the insertion process of the hairpin wire butt joint 121 into the clamping groove 21 smoother.

[0099] The above are only specific application examples of the present invention and do not constitute any limitation to the protection scope of the present invention. Any technical solutions formed by equivalent transformation or equivalent replacement shall fall within the protection scope of the present invention.

Claims

1. A welding device for hairpin wire of a flat wire motor stator, characterized in that: It includes a laser welding unit, a blocking block, a cutting mechanism and a motion adjustment unit; The cutting mechanism is used to cut each hairpin wire butt joint of the flat wire motor stator on a first side surface in a tangential direction of the flat wire motor stator, so as to form a welding bevel on a side of the top end of each hairpin wire butt joint close to the first side surface; The motion adjustment unit is used to drive the stator of the flat wire motor and the blocking block to move relative to each other, so as to move the blocking block to the outside of the second side surface opposite to the first side surface of any hairpin wire butt joint; the motion adjustment unit is also used to adjust the focus of the laser welding unit to the welding inclined surface of the hairpin wire butt joint after the blocking block is moved to the outside of the second side surface of any hairpin wire butt joint; The laser welding unit is used to perform laser welding on the welding bevel of the hairpin wire butt joint, so as to weld the ends of the two hairpin wires at the hairpin wire butt joint into one; The blocking block is used to block the leakage light emitted from the gap between the ends of two hairpin wires at the hairpin wire butt joint when the laser welding unit performs laser welding on the hairpin wire butt joint.

2. The welding device for hairpin wire of flat wire motor stator according to claim 1, characterized in that: The blocking block is used to open a clamping groove on one side facing the second side surface, and the clamping groove is opened along the axial direction of the flat wire motor stator. The motion adjustment unit is used to drive the flat wire motor stator and the blocking block to move relative to each other, so as to move the blocking block to the outside of the second side surface of any hairpin wire butt joint, and insert the hairpin wire butt joint into the clamping groove to limit the gap distance between the ends of the two hairpin wires at the hairpin wire butt joint.

3. The welding device for hairpin wire of flat wire motor stator according to claim 2, characterized in that: The blocking block is provided with a plurality of clamping grooves; each of the clamping grooves is arranged along the radial direction of the stator of the flat wire motor; The motion adjustment unit is used to drive the flat wire motor stator and the blocking block to move relative to each other, so as to insert the multiple hairpin wire docking connectors arranged radially along the flat wire motor stator of any hairpin wire docking unit among the multiple hairpin wire docking units arranged circumferentially on the flat wire motor stator into different clamping grooves respectively.

4. The welding device for hairpin wire of flat wire motor stator according to any one of claims 2 and 3, characterized in that: The notch of the clamping groove is provided with a guiding inclined surface.

5. The welding device for hairpin wire of flat wire motor stator according to any one of claims 2 and 3, characterized in that: The width of the clamping groove is equal to the sum of twice the thickness of the end of the hairpin wire and the preset gap value; The preset gap value ranges from 1.5 mm to 2 mm.

6. The welding device for hairpin wire of flat wire motor stator according to claim 4, characterized in that: The chamfer angle of the guide slope ranges from 30 degrees to 60 degrees.

7. The welding device for hairpin wire of flat wire motor stator according to claim 3, characterized in that: The motion adjustment unit includes a first motion mechanism, a second motion mechanism and an adjustment mechanism; The first motion mechanism is used to clamp and position the flat wire motor stator, and the first motion mechanism is also used to drive the flat wire motor stator to rotate around its central axis to rotate any of the hairpin wire docking units to a welding station; The output end of the second motion mechanism is fixedly connected to the blocking block, and the second motion mechanism is used to drive the blocking block to approach the welding end of the flat wire motor stator or to move away from the flat wire motor stator along the axial direction of the flat wire motor stator; the second motion mechanism is also used to drive the blocking block to reciprocate along the tangential straight line of the flat wire motor stator, so as to insert a plurality of hairpin wire butt joints arranged along the radial direction of the flat wire motor stator of any hairpin wire butt joint unit rotated to the welding station into different clamping grooves, or to pull out each hairpin wire butt joint from each clamping groove; The adjusting mechanism is used to adjust the focus of the laser welding unit to the welding inclined surface of each hairpin wire butt joint of the hairpin wire butt joint unit located on the welding station.

8. A method for welding a hairpin wire of a flat wire motor stator, characterized in that: The welding method is realized based on the welding device of the hairpin wire of the flat wire motor stator according to any one of claims 1 to 7, and comprises: Using a cutting mechanism to cut the first side surface of each hairpin wire butt joint of the flat wire motor stator in the tangential direction of the flat wire motor stator, so as to form a welding bevel on one side of the top end of each hairpin wire butt joint close to the first side surface; The motion adjustment unit is used to drive the stator of the flat wire motor and the blocking block to move relative to each other, so as to move the blocking block to the outside of the second side surface opposite to the first side surface of any hairpin wire butt joint that has not been welded; and the focus of the laser welding unit is adjusted to the welding inclined surface of the hairpin wire butt joint; The laser welding unit is used to perform laser welding on the welding bevel of the hairpin wire butt joint to weld the ends of the two hairpin wires at the hairpin wire butt joint into one. After completing the welding of the hairpin wire butt joint, continue to weld other hairpin wire butt joints that have not yet been welded.

9. The method for welding the hairpin wire of the flat wire motor stator according to claim 8, characterized in that: Use the following steps to weld the hairpin wire butt joint: Step 1: using the motion adjustment unit to drive the flat wire motor stator and the blocking block to move relative to each other, so as to insert a plurality of hairpin wire butt joints arranged along the radial direction of the flat wire motor stator of any hairpin wire butt joint unit that has not been welded among a plurality of hairpin wire butt joint units arranged along the circumferential direction on the flat wire motor stator into different clamping grooves on the blocking block respectively; Step 2: using the motion adjustment unit to adjust the focus of the laser welding unit to the welding slope of any unwelded hairpin wire butt joint of the hairpin wire butt joint unit; Step 3: Use the laser welding unit to perform laser welding on the welding bevel of the hairpin wire butt joint. After completing the welding of the hairpin wire butt joint, return to step 2; until all the hairpin wire butt joints of the hairpin wire butt joint unit are welded, check whether the welding of all the hairpin wire butt joints of the flat wire motor stator is completed. If not, proceed to step 4; Step 4: Use the motion adjustment unit to drive the flat wire motor stator and the blocking block to move relative to each other, so as to pull out the welded hairpin wire butt joints from the clamping grooves on the blocking block, and then insert multiple hairpin wire butt joints of the next hairpin wire docking unit that have not yet been welded and are arranged radially along the flat wire motor stator into different clamping grooves on the blocking block, and then return to step 2.

10. The method for welding hairpin wires of a flat wire motor stator according to claim 9, characterized in that: The step 4 includes the following sub-steps: S401: using the second motion mechanism of the motion adjustment unit to drive the blocking block to move tangentially along the stator of the flat wire motor, so as to extract the welded hairpin wire butt joints from the clamping grooves on the blocking block; S402: using the second motion mechanism to drive the blocking block away from the flat wire motor stator along the axial direction of the flat wire motor stator, so that the blocking block moves to the outside of the welding end of the flat wire motor stator; S403: using the first motion mechanism of the motion adjustment unit to drive the stator of the flat wire motor to rotate around its central axis, so as to rotate the next hairpin wire docking unit that has not been welded to the welding station; S404: using the second motion mechanism to drive the blocking block along the axial direction of the flat wire motor stator to approach the welding end of the flat wire motor stator, so as to move the blocking block to the outside of the second side surface of each hairpin wire butt joint of the hairpin wire butt joint unit located at the welding station; S405: Use the second motion mechanism to drive the blocking block to move tangentially along the stator of the flat wire motor, so as to insert the multiple hairpin wire docking joints arranged radially along the stator of the flat wire motor of the hairpin wire docking unit rotated to the welding station into different clamping grooves on the blocking block, and then return to step 2.

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