A welding device and welding method for hairpin wires of a stator of a flat wire motor
By forming a welding bevel on the stator of a flat wire motor and using a blocking block to limit the gap, the problem of light leakage in laser welding of the stator of a flat wire motor is solved, ensuring welding quality and motor performance.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- ZHIXIN TECH CO LTD
- Filing Date
- 2024-10-14
- Publication Date
- 2026-07-21
AI Technical Summary
In the existing laser welding process for flat wire motor stators, there is a gap between the ends of the two hairpin wires at the hairpin wire joint, which leads to the risk of light leakage, makes it difficult to install a protective plate, causes damage to the copper wire coating, and affects the motor performance.
A cutting mechanism is used to form a welding bevel on the tangential side of the stator of the flat wire motor. The blocking block is moved to the outside of the hairpin wire mating joint by a blocking block and a motion adjustment unit. The gap is limited by the clamping groove to block light leakage. The laser welding unit is used to weld on the bevel.
This effectively prevents light leakage from directly illuminating the lower copper wires, ensuring welding quality, reducing damage to the copper wire coating, improving the motor's voltage resistance, and preventing the motor from becoming unusable.
Smart Images
Figure CN119457420B_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of flat wire motor technology, specifically relating to a welding device and welding method for the hairpin wire of a flat wire motor stator. Background Technology
[0002] The research and development and manufacturing of automotive electric drive systems are the core links in the realization of electrification in the automotive industry. 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 system. The design, research and development and manufacturing of the flat wire motor stator are important guarantees for achieving high power density and compact design of automotive electric drive systems.
[0003] The current manufacturing process for flat wire motor stators mainly consists of hairpin wire forming, slotting, flaring and twisting, cutting, welding, coating, and paint application. Hairpin wire welding primarily employs two processes: TIG welding and laser welding. Compared to TIG welding, laser welding effectively improves the welding efficiency and quality of flat wire motor stators, and is currently the industry standard for hairpin wire welding. Before laser welding, the hairpin wire to be welded is fixed using grippers or a tooling tray, then positioned by a vision system before being scanned and welded by the laser one or more times.
[0004] In existing hairpin wire laser welding processes, the ends of each hairpin wire joint on the stator of a flat wire motor are typically cut flat before a laser welding device is used to emit a laser along the axial direction of the stator to weld the top surfaces of each hairpin wire joint, thus bonding the ends of the two hairpin wires at the joint together. However, because there is a gap between the ends of the two hairpin wires at the joint during welding, and because the laser is emitted vertically to the top surface of the joint, there is often a risk of light leakage during the welding process. Furthermore, it is difficult to install a protective plate for this, resulting in light leakage from the gap between the ends of the two hairpin wires directly irradiating the underlying copper wire, causing damage to the copper wire coating. This can lead to the motor failing the withstand voltage test during electrical testing, ultimately potentially rendering the motor unusable. Summary of the Invention
[0005] To address the shortcomings of the prior art, this invention provides a welding device and method for the hairpin wires of a flat wire motor stator. This solves the problem that in existing hairpin wire laser welding processes, a gap exists between the ends of the two hairpin wires at the hairpin wire joint during welding. Furthermore, the laser is emitted vertically to the top surface of the hairpin wire joint during laser welding, leading to a risk of light leakage. It is difficult to install a protective plate for this, resulting in the laser energy directly irradiating the lower copper wire, causing damage to the copper wire coating, and ultimately resulting in the motor failing the withstand voltage test and potentially rendering the motor unusable.
[0006] To achieve the above objectives, the technical solution of the present invention is as follows:
[0007] A welding device for the hairpin wire of a flat wire motor stator includes 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 the first side of the flat wire motor stator in the tangential direction, so as to form a welding bevel on the top of each hairpin wire butt joint near the first side.
[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 opposite the first side of any of the hairpin wire docking joints (that is, the side of the second side away from the first side); the motion adjustment unit is also used to adjust the focus of the laser welding unit to the welding slope of the hairpin wire docking joint after the blocking block is moved to the outside of the second side of any of the hairpin wire docking joints;
[0010] 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 piece.
[0011] The blocking block is used to block light leakage from the gap between the ends of the two hairpins at the hairpin wire joint during the laser welding process of the laser welding unit on the hairpin wire joint.
[0012] The cutting mechanism cuts each hairpin wire joint of the flat wire motor stator on the first side of the flat wire motor stator along the tangential direction, forming a welding bevel on the top of each hairpin wire joint near the first side. Then, the motion adjustment unit drives the flat wire motor stator and the blocking block to move relative to each other, moving the blocking block to the outside of the second side opposite the first side of any hairpin wire joint. During the laser welding process of the laser welding unit on the welding bevel of any hairpin wire joint, the blocking block, positioned outside the second side of the hairpin wire joint, prevents the hairpin wire from entering the joint. This method effectively prevents light leakage from the gap between the ends of the two hairpin wires from directly irradiating the lower copper wire. It solves the problem that in existing hairpin wire laser welding processes, there is often a risk of light leakage during welding due to the gap between the ends of the two hairpin wires at the joint. Furthermore, the laser is emitted vertically to the top surface of the joint during laser welding, which makes it difficult to install a protective plate. This results in the laser energy directly irradiating the lower copper wire, causing damage to the copper wire coating, which in turn leads to the motor failing the withstand voltage test and potentially rendering the motor unusable.
[0013] Furthermore, the blocking block is provided with a clamping groove on one side facing the second side, the clamping groove being opened along the axial direction of the flat wire motor stator, and 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 of any of the hairpin wire docking joints, and insert the hairpin wire docking joint into the clamping groove, so as to limit the gap distance between the ends of the two hairpin wires at the hairpin wire docking joint.
[0014] By creating a clamping groove on the side of the blocking block facing the second side, before the laser welding unit performs laser welding on the welding bevel of any hairpin wire joint, the gap between the ends of the two hairpin wires at the hairpin wire joint can be limited by inserting the hairpin wire joint into the clamping groove. This achieves the effect of controlling the welding gap between the ends of the two hairpin wires at the hairpin wire joint, ensuring the welding quality of the hairpin wire joint and reducing light leakage from the gap between the ends of the two hairpin wires at the hairpin wire joint.
[0015] The bottom of the clamping groove is used to block light leakage from the gap between the ends of the two hairpins at the hairpin wire joint during the laser welding process of the laser welding unit on the hairpin wire joint.
[0016] Furthermore, the blocking block is provided with a plurality of clamping grooves; each clamping groove is arranged radially along 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 joints of any one of the multiple hairpin wire docking units arranged circumferentially on the flat wire motor stator into different clamping slots.
[0018] Furthermore, the opening of the clamping groove is provided with a guide slope.
[0019] By setting a guide slope at the opening of the clamping groove, the hairpin wire connector can be prevented from colliding, being squeezed, or being cut by the blocking block due to positioning errors and excessive gap between the ends of the two hairpin wires at the hairpin wire connector during the insertion of the hairpin wire connector into the clamping groove. This would also prevent damage to the hairpin wire connector and make the insertion process of the hairpin wire connector into the clamping groove smoother.
[0020] Furthermore, the width of the clamping groove is equal to the sum of twice the end thickness of the hairpin wire and the preset gap value; the preset gap value ranges from 1.5 mm to 2 mm.
[0021] Furthermore, the chamfer of the guide slope ranges from 30 degrees to 60 degrees.
[0022] Preferably, the chamfer of the guide slope is 45 degrees.
[0023] Furthermore, 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 the welding station.
[0025] The output end of the second motion mechanism is fixedly connected to the blocking block. The second motion mechanism is used to drive the blocking block to move closer to or away from the welding end of 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 linear direction of the flat wire motor stator, so as to insert multiple hairpin wire docking joints arranged radially along the flat wire motor stator of any hairpin wire docking unit rotated to the welding station into different clamping slots, or to pull each hairpin wire docking joint out of each clamping slot.
[0026] The adjustment mechanism is used to adjust the focus of the laser welding unit to the welding bevel of each hairpin wire joint of the hairpin wire docking unit located at the welding station.
[0027] According to the welding apparatus for the hairpin wire of the flat wire motor stator provided by the present invention, the present invention also provides a welding method for the hairpin wire of the flat wire motor stator, the welding method comprising:
[0028] The hairpin wire mating joints of the flat wire motor stator are cut on the first side of the flat wire motor stator in the tangential direction using a cutting mechanism, so that a welding bevel is formed on the top of each hairpin wire mating joint near the first side.
[0029] The motion adjustment unit drives 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 opposite the first side of any hairpin wire butt joint that has not yet been welded; and adjusts the focus of the laser welding unit to the welding slope 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 piece. After the welding of the hairpin wire butt joint is completed, the welding of other hairpin wire butt joints that have not yet been welded is continued.
[0031] Furthermore, the hairpin wire connector is welded using the following steps:
[0032] Step 1: 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 insert the multiple hairpin wire docking joints of any hairpin wire docking unit that has not yet been welded along the radial direction of the flat wire motor stator into different clamping slots on the blocking block respectively.
[0033] Step 2: Use the motion adjustment unit to adjust the focus of the laser welding unit to the welding bevel of any unwelded hairpin wire joint of the hairpin wire docking 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. Continue until the welding of all hairpin wire butt joints of the hairpin wire butt unit is completed. Then check whether the welding of all 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 each hairpin wire mating joint that has been welded from each clamping groove on the blocking block. Then, insert the multiple hairpin wire mating joints of the next hairpin wire mating unit that has not yet been welded into different clamping grooves on the blocking block, and then return to step 2.
[0036] Furthermore, step 4 includes the following sub-steps:
[0037] S401: The second motion mechanism of the motion adjustment unit drives the blocking block to move tangentially along the stator of the flat wire motor, so as to pull out each hairpin wire butt joint that has been welded from each clamping groove on the blocking block;
[0038] S402: The second motion mechanism drives 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 welded end of the flat wire motor stator;
[0039] S403: The first motion mechanism of the motion adjustment unit drives the stator of the flat wire motor to rotate around its central axis to rotate the next hairpin wire docking unit that has not yet been welded to the welding station.
[0040] S404: The second motion mechanism drives the blocking block to approach the welding end of the flat wire motor stator along the axial direction of the flat wire motor stator, so as to move the blocking block to the outside of the second side of each hairpin wire docking joint of the hairpin wire docking unit located at the welding station;
[0041] S405: Using 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 of the hairpin wire docking unit, which has been rotated to the welding station and is arranged radially along the stator of the flat wire motor, into different clamping slots on the blocking block, and then return to step 2. Attached Figure Description
[0042] To more clearly illustrate the technical solution of the present invention, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0043] Figure 1 This is a schematic diagram of the hairpin wire connector before cutting in Example 1;
[0044] Figure 2This is a schematic diagram of the structure of the cut hairpin wire connector in Example 1;
[0045] Figure 3 This is a schematic diagram of the stator structure of the flat wire motor in Example 1;
[0046] Figure 4 This is a schematic diagram of the mating relationship between the blocking block and the hairpin wire connector in Example 1. Figure 1 ;
[0047] Figure 5 This is a schematic diagram of the mating relationship between the blocking block and the hairpin wire connector in Example 1. Figure 2 ;
[0048] Figure 6 This is a schematic 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 wire docking unit;
[0051] 121—Hairpin wire connector;
[0052] 1211—Top surface, 1212—First side surface, 1213—Second side surface, 1214—Welding bevel;
[0053] 21—Clamping groove, 22—Guide slope. Detailed Implementation
[0054] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.
[0055] like Figure 1 As shown, in existing hairpin wire laser welding processes, the ends of each hairpin wire joint 121 of the flat wire motor stator are usually cut flat before a laser welding device is used to emit a laser along the axial direction of the flat wire motor stator to laser weld the top surface 1211 of each hairpin wire joint 121, so as to weld the ends of the two hairpin wires at the hairpin wire joint 121 into one piece. However, since there is a gap between the ends of the two hairpin wires at the hairpin wire joint 121 during welding, and the laser is emitted vertically to the top surface 1211 of the hairpin wire joint 121 during laser welding, there is usually a risk of light leakage during the welding process. It is also difficult to set up a protective plate for protection, which leads to the light leakage from the gap between the ends of the two hairpin wires directly irradiating the lower copper wire, causing damage to the copper wire coating, which in turn causes the withstand voltage to fail during motor electrical testing, and may eventually lead to the scrapping of the motor.
[0056] Example 1:
[0057] To solve the above problems, such as Figures 1 to 6 As shown, Embodiment 1 provides a welding device for the hairpin wire of a flat wire motor stator, including 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 mating 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 top of each hairpin wire mating joint 121 near 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 1213 opposite to the first side 1212 of any hairpin wire mating joint 121 (that is, the side of the second side 1213 away from the first side 1212); the motion adjustment unit is also used to adjust the focus of the laser welding unit to the welding slope 1214 of the hairpin wire mating joint 121 after the blocking block 2 is moved to the outside of the second side 1213 of any hairpin wire mating joint 121.
[0060] 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 piece.
[0061] The blocking block 2 is used to block the light leakage emitted from the gap between the ends of the two hairpins at the hairpin wire connector 121 during the laser welding process of the hairpin wire connector 121 in the laser welding unit.
[0062] The cutting mechanism cuts the first side 1212 of each hairpin wire mating joint 121 on the tangential direction of the flat wire motor stator 1, so that a welding bevel 1214 is formed on the top of each hairpin wire mating joint 121 near the first side 1212. Then, the motion adjustment unit drives the flat wire motor stator 1 and the blocking block 2 to move relative to each other, so that the blocking block 2 is moved to the outside of the second side 1213 opposite to the first side 1212 of any hairpin wire mating joint 121. During the laser welding process of the laser welding unit on the welding bevel 1214 of any hairpin wire mating joint 121, the blocking block 2, which blocks the second side 1213 of the hairpin wire mating joint 121, prevents the hairpin wire from entering through the second side 1213. The light leakage emitted from the gap between the ends of the two hairpin wires at the hairpin wire connector 121 can effectively prevent the light leakage from the gap between the ends of the two hairpin wires from directly irradiating the lower copper wire. This solves the technical problem that in the existing hairpin wire laser welding process, because there is a gap between the ends of the two hairpin wires at the hairpin wire connector 121 during welding, and the laser is emitted vertically to the top surface 1211 of the hairpin wire connector 121 during laser welding, there is usually a risk of light leakage during the welding process, and it is difficult to set up a protective plate for protection. As a result, the laser energy directly irradiates the lower copper wire, causing damage to the copper wire coating, which in turn leads to the failure of the withstand voltage during motor electrical testing, and may ultimately lead to the scrapping of the motor.
[0063] In one embodiment, such as Figures 4 to 6 As shown, the blocking block 2 has a clamping groove 21 on the side facing the second side 1213. 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 opening a clamping groove 21 on the side of the blocking block 2 facing the second side 1213, before the laser welding unit performs laser welding on the welding slope 1214 of any hairpin wire butt joint 121, the gap distance between the ends of the two hairpin wires at the hairpin wire butt joint 121 can be limited by inserting the hairpin wire butt joint 121 into the clamping groove 21. This achieves 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 reduce the light leakage 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 light leakage from the gap between the ends of the two hairpins at the hairpin wire connector 121 during the laser welding process of the laser welding unit on the hairpin wire connector 121.
[0066] In one embodiment, such as Figures 4 to 6 As shown, the blocking block 2 is provided with multiple clamping slots 21; each clamping slot 21 is arranged radially along the stator 1 of the flat wire motor.
[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 of any hairpin wire docking unit 12 arranged circumferentially on the flat wire motor stator 1 into different clamping slots 21 respectively.
[0068] The number of clamping slots 21 on the blocking block 2 is at least greater than the number of hairpin wire docking connectors 121 arranged radially along the flat wire motor stator 1 included in the hairpin wire docking unit 12.
[0069] In this embodiment 1, each hairpin wire docking unit 12 includes three hairpin wire docking connectors 121 arranged radially along the stator 1 of the flat wire motor, and three clamping grooves 21 are also correspondingly provided on the blocking block 2.
[0070] Preferably, in this embodiment 1, as Figure 6 As shown, the opening of the clamping groove 21 is provided with a guide slope 22.
[0071] By setting a guide slope 22 at the opening of the clamping groove 21, the hairpin wire connector 121 can be inserted into the clamping groove 21 without being damaged by factors such as positioning error and excessive gap between the ends of the two hairpin wires at the hairpin wire connector 121, which could cause the hairpin wire connector 121 to collide, squeeze, or cut with the blocking block 2. This also makes the process of inserting the hairpin wire connector 121 into the clamping groove 21 smoother.
[0072] Preferably, in this embodiment 1, the width of the clamping groove 21 is equal to the sum of twice the end thickness of the hairpin wire and the preset gap value; the preset gap value ranges from 1.5 mm to 2 mm.
[0073] In one embodiment, the chamfer 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, as 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. The first motion mechanism is also used to drive the flat wire motor stator 1 to rotate around its central axis so as 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. The second motion mechanism 3 is used to drive the blocking block 2 to approach or move away from the welding end 11 of 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 linear direction of the flat wire motor stator 1, 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 rotated to the welding station into different clamping slots 21, or to pull each hairpin wire docking joint 121 out of each clamping slot 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 mating joint 121 of the hairpin wire mating unit 12 located at the welding station.
[0079] Example 2:
[0080] Based on the welding device for the hairpin wire of the flat wire motor stator provided in Embodiment 1, Embodiment 2 provides a welding method for the hairpin wire of the flat wire motor stator, the welding method including:
[0081] The first side 1212 of each hairpin wire mating joint 121 of the flat wire motor stator 1 in the tangential direction of the flat wire motor stator 1 is cut using a cutting mechanism, so that a welding bevel 1214 is formed on the top of each hairpin wire mating joint 121 near the first side 1212.
[0082] The motion adjustment unit drives the stator 1 of the flat wire motor 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 opposite to the first side 1212 of any hairpin wire butt joint 121 that has not yet been welded; and adjust the focus of the laser welding unit to the welding slope 1214 of the hairpin wire butt joint 121.
[0083] The welding bevel 1214 of the hairpin wire butt joint 121 is laser welded using a laser welding unit to weld the ends of the two hairpin wires at the hairpin wire butt joint 121 into one piece. After the welding of the hairpin wire butt joint 121 is completed, the welding of other hairpin wire butt joints 121 that have not yet been welded is continued.
[0084] The following steps are used to weld the hairpin wire connector 121:
[0085] Step 1: Drive the flat wire motor stator 1 and the blocking block 2 to move relative to each other using the motion adjustment unit, so that multiple hairpin wire docking joints 121 of any hairpin wire docking unit 12 that has not yet been welded, which is arranged radially along the flat wire motor stator 1, are respectively inserted into different clamping slots 21 on the blocking block 2.
[0086] Step 2: Use the motion adjustment unit to adjust the focus of the laser welding unit to the welding bevel 1214 of any hairpin wire mating joint 121 that has not yet been welded in the hairpin wire mating unit 12;
[0087] Step 3: Use the laser welding unit to perform laser welding on the welding bevel 1214 of the hairpin wire butt joint 121. After completing the welding of the hairpin wire butt joint 121, return to step 2. Continue until the welding of all hairpin wire butt joints 121 of the hairpin wire butt unit 12 is completed. Then check whether the welding of all hairpin wire butt joints 121 of the flat wire motor stator 1 is completed. If not, proceed 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 each hairpin wire mating joint 121 that has been welded from each clamping groove 21 on the blocking block 2. Then, insert the multiple hairpin wire mating joints 121 of the next hairpin wire mating unit 12 that have not yet been welded into different clamping grooves 21 on the blocking block 2, and then return to step 2.
[0089] Step 4 above includes the following sub-steps:
[0090] S401: The second motion mechanism 3 of the motion adjustment unit drives the blocking block 2 to move tangentially along the stator 1 of the flat wire motor (specifically, to...). Figure 4 Taking the direction in the middle as an example, that is, using the second motion mechanism 3 of the motion adjustment unit to drive the blocking block 2 to move to the right along the tangential direction of the flat wire motor stator 1, so as to pull out each hairpin wire butt joint 121 that has been welded from each clamping groove 21 on the blocking block 2.
[0091] S402: The second motion mechanism 3 drives 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: The first motion mechanism of the motion adjustment unit drives the stator 1 of the flat wire motor to rotate around its central axis, so as to rotate the next hairpin wire docking unit 12 that has not yet been welded to the welding station.
[0093] S404: The second motion mechanism 3 drives the blocking block 2 to approach the welding end 11 of the flat wire motor stator 1 along the axial direction of the flat wire motor stator 1, so as to move the blocking block 2 to the outside of the second side 1213 of each hairpin wire docking joint 121 of the hairpin wire docking unit 12 located at the welding station.
[0094] S405: The second motion mechanism 3 drives the blocking block 2 to move tangentially along the stator 1 of the flat wire motor (specifically, to...). Figure 4 Taking the direction in the middle as an example, that is, using the second motion mechanism 3 of the motion adjustment unit to drive the blocking block 2 to move to the left along the tangential direction of the flat wire motor stator 1, so as to insert the multiple hairpin wire docking joints 121 of the hairpin wire docking unit 12, which is rotated to the welding station, along the radial direction of the flat wire motor stator 1 into different clamping slots 21 on the blocking block 2, and then return to step 2.
[0095] The welding device and welding method for 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. A cutting mechanism is used to cut the first side 1212 of each hairpin wire mating joint 121 on the tangential direction of the flat wire motor stator 1, so that a welding bevel 1214 is formed on the top of each hairpin wire mating joint 121 near the first side 1212. Then, a motion adjustment unit drives the flat wire motor stator 1 and the blocking block 2 to move relative to each other, so that the blocking block 2 is moved to the outside of the second side 1213 opposite to the first side 1212 of any hairpin wire mating joint 121. During the laser welding process of the laser welding unit on the welding bevel 1214 of any hairpin wire mating joint 121, the blocking block 2, which blocks the second side 1213 of the hairpin wire mating joint 121, prevents the hairpin wire mating joint 121 from entering through the second side 1213. The light leakage emitted from the gap between the ends of the two hairpin wires at the hairpin wire connector 121 can effectively prevent the light leakage from the gap between the ends of the two hairpin wires from directly irradiating the lower copper wire. This solves the technical problem that in the existing hairpin wire laser welding process, because there is a gap between the ends of the two hairpin wires at the hairpin wire connector 121 during welding, and the laser is emitted vertically to the top surface 1211 of the hairpin wire connector 121 during laser welding, there is usually a risk of light leakage during the welding process, and it is difficult to set up a protective plate for protection. As a result, the laser energy directly irradiates the lower copper wire, causing damage to the copper wire coating, which in turn leads to the failure of the withstand voltage during motor electrical testing, and may ultimately lead to the scrapping of the motor.
[0097] 2. By opening a clamping groove 21 on the side of the blocking block 2 facing the second side 1213, before the laser welding unit performs laser welding on the welding slope 1214 of any hairpin wire butt joint 121, the gap distance between the ends of the two hairpin wires at the hairpin wire butt joint 121 can be limited by inserting the hairpin wire butt joint 121 into the clamping groove 21. This achieves 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 reduce the light leakage emitted from the gap between the ends of the two hairpin wires at the hairpin wire butt joint 121.
[0098] 3. By setting a guide slope 22 at the opening of the clamping groove 21, the hairpin wire connector 121 can be inserted into the clamping groove 21 without being damaged by factors such as positioning error and excessive gap between the ends of the two hairpin wires at the hairpin wire connector 121, which could cause the hairpin wire connector 121 to collide, squeeze, or cut with the blocking block 2. This also makes the process of inserting the hairpin wire connector 121 into the clamping groove 21 smoother.
[0099] The above are merely specific application examples of the present invention and do not constitute any limitation on the scope of protection of the present invention. All technical solutions formed by equivalent transformation or equivalent substitution fall within the scope of protection of the present invention.
Claims
1. A welding device for the hairpin wire of a flat wire motor stator, characterized in that: 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 the first side of the flat wire motor stator in the tangential direction, so as to form a welding bevel on the top of each hairpin wire butt joint near the first side. 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 opposite to the first side 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 slope of the hairpin wire butt joint after moving the blocking block to the outside of the second side 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 to weld the ends of the two hairpin wires at the hairpin wire butt joint into one piece. The blocking block is used to block the light leakage emitted from the gap between the ends of the two hairpin wires at the hairpin wire joint during the laser welding process of the laser welding unit, so as to prevent the light leakage emitted from the gap between the ends of the two hairpin wires from directly irradiating the lower copper wire. The blocking block is provided with a clamping groove on one side facing the second side. The clamping groove is provided 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 of any of the hairpin wire docking joints and insert the hairpin wire docking joint into the clamping groove, so as to limit the gap distance between the ends of the two hairpin wires at the hairpin wire docking joint.
2. The welding device for the hairpin wire of the flat wire motor stator according to claim 1, characterized in that: The blocking block is provided with a plurality of clamping slots; each clamping slot is arranged radially along 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 joints of any one of the multiple hairpin wire docking units arranged circumferentially on the flat wire motor stator into different clamping slots.
3. The welding device for the hairpin wire of the flat wire motor stator according to any one of claims 1 and 2, characterized in that: The opening of the clamping groove is provided with a guide slope.
4. The welding device for the hairpin wire of the flat wire motor stator according to any one of claims 1 and 2, characterized in that: The width of the clamping groove is equal to the sum of twice the end thickness of the hairpin wire and the preset gap value; The preset gap value ranges from 1.5 mm to 2 mm.
5. The welding device for the hairpin wire of the flat wire motor stator according to claim 3, characterized in that: The chamfer of the guide slope ranges from 30 degrees to 60 degrees.
6. The welding device for the hairpin wire of the flat wire motor stator according to claim 2, 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 the welding station. The output end of the second motion mechanism is fixedly connected to the blocking block. The second motion mechanism is used to drive the blocking block to move closer to or away from the welding end of 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 linear direction of the flat wire motor stator, so as to insert multiple hairpin wire docking joints arranged radially along the flat wire motor stator of any hairpin wire docking unit rotated to the welding station into different clamping slots, or to pull each hairpin wire docking joint out of each clamping slot. The adjustment mechanism is used to adjust the focus of the laser welding unit to the welding bevel of each hairpin wire joint of the hairpin wire docking unit located at the welding station.
7. A method for welding hairpin wires to the stator of a flat wire motor, characterized in that, The welding method is implemented using a welding device for the hairpin wire of a flat wire motor stator as described in any one of claims 1-6, and the welding method includes: The hairpin wire mating joints of the flat wire motor stator are cut on the first side of the flat wire motor stator in the tangential direction using a cutting mechanism, so that a welding bevel is formed on the top of each hairpin wire mating joint near the first side. The motion adjustment unit drives 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 opposite the first side of any hairpin wire butt joint that has not yet been welded; and adjusts the focus of the laser welding unit to the welding slope 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 piece. After the welding of the hairpin wire butt joint is completed, the welding of other hairpin wire butt joints that have not yet been welded is continued.
8. The welding method for the hairpin wire of the flat wire motor stator according to claim 7, characterized in that: The following steps are used to weld the hairpin wire connector: Step 1: 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 insert the multiple hairpin wire docking joints of any hairpin wire docking unit that has not yet been welded along the radial direction of the flat wire motor stator into different clamping slots on the blocking block respectively. Step 2: Use the motion adjustment unit to adjust the focus of the laser welding unit to the welding bevel of any unwelded hairpin wire joint of the hairpin wire docking 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. Continue until the welding of all hairpin wire butt joints of the hairpin wire butt unit is completed. Then check whether the welding of all 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 each hairpin wire mating joint that has been welded from each clamping groove on the blocking block. Then, insert the multiple hairpin wire mating joints of the next hairpin wire mating unit that has not yet been welded into different clamping grooves on the blocking block, and then return to step 2.
9. The welding method for the hairpin wire of the flat wire motor stator according to claim 8, characterized in that: Step 4 includes the following sub-steps: S401: The second motion mechanism of the motion adjustment unit drives the blocking block to move tangentially along the stator of the flat wire motor, so as to pull out each hairpin wire butt joint that has been welded from each clamping groove on the blocking block; S402: The second motion mechanism drives 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 welded end of the flat wire motor stator; S403: The first motion mechanism of the motion adjustment unit drives the stator of the flat wire motor to rotate around its central axis to rotate the next hairpin wire docking unit that has not yet been welded to the welding station. S404: The second motion mechanism drives the blocking block to approach the welding end of the flat wire motor stator along the axial direction of the flat wire motor stator, so as to move the blocking block to the outside of the second side of each hairpin wire docking joint of the hairpin wire docking unit located at the welding station; S405: Using 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 of the hairpin wire docking unit, which has been rotated to the welding station and is arranged radially along the stator of the flat wire motor, into different clamping slots on the blocking block, and then return to step 2.