X-Pin stator production process and method

Abstract

The invention discloses an X-Pin stator production process and method, and relates to the technical field of flat wire motor stator production, and the X-Pin stator production process comprises a wire forming station, a paper inserting station, a wire inserting station, a wire pressing station, a flaring station, a head twisting station, a welding station, an electric testing station, a paint dripping station and a coating station. According to the production process route provided by the invention, a head cutting station is omitted, head cutting operation on the copper wire is not needed, the equipment cost is saved, meanwhile, the loss of the copper wire is reduced, and the production cost is effectively saved, so that the produced X-Pin stator is excellent in performance.

Description

Technical Field

[0001] The invention relates to the technical field of flat wire motor stator production, and in particular to an X-Pin stator production process and method. Background Art

[0002] The existing flat wire motor has a straight section of about 10mm at the welding end. If it is removed to reduce the size of the copper wire end, the motor copper consumption can be reduced, the efficiency can be improved, and the motor size can be reduced. Because the copper wire overlap position is X-shaped, it is called X-Pin stator; because of these advantages, major stator manufacturers are actively launching X-Pin stator products. Because the X-Pin stator cancels the straight section, the existing production process and equipment have very small operating space for clamping the stator copper wire and cannot meet production needs, making the manufacturing of the X-Pin stator difficult, so a new set of production processes and methods are needed as support. Summary of the invention

[0003] The object of the present invention is to provide an X-Pin stator production process and method to solve the problem that the manufacturing of the X-Pin stator is difficult and the existing production process and equipment are difficult to meet the production requirements as mentioned in the above background technology.

[0004] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: an X-Pin stator production process and method, the X-Pin stator includes a stator core e and a copper wire winding f, the copper wire winding f is mainly formed by multi-layer flat copper wire windings, including a crown end and a welding end, and the bending line type of the copper wire includes multiple line types a, b, c, and d; the outer diameter of the stator core e is 224 mm, the inner diameter of the stator core e is 157.5 mm, the height of the stator core e is 86 mm, the number of slots of the stator core e is 72 slots, the height of the crown end of the stator winding f is 27.25 mm, the height of the welding end is 30 mm, and the torsion angle of the copper wire is 25°; the production process includes, from front to back, a wire forming station, a paper inserting station, a wire inserting station, a wire pressing station, a flaring station, a head twisting station, a welding station, an electrical testing station, a paint dripping station, and a coating station.

[0005] Furthermore, the wire forming station is provided with a flat copper wire straightening, paint stripping, cutting device and a wire forming device. At the flat copper wire straightening, paint stripping and cutting device, the flat copper wire is first straightened, and then the corresponding wire foot shape and the length of the flat copper wire to be cut are determined according to the shapes of wire type a, wire type b, wire type c and wire type d. After the determination is completed, the corresponding cutter position is determined on the straightened flat copper wire and the corresponding cutter structure is designed, and the flat copper wire at the corresponding position is paint stripped. After paint stripping, the flat copper wire is cut at the cutter position accordingly, and the flat copper wire is cut into multiple sections of straight flat copper wire. At the same time, the wire foot is cut into an inclined surface or an arc surface while the copper wire is cut; then the straight flat copper wire is transferred to the wire forming device for 2D and 3D mold stamping to make a U-shaped wire; the paper insertion station includes an insulating paper forming device, which is used to roll and cut the insulating paper and perform corresponding bending operations, and the bent insulating paper is transferred to the wire insertion station.

[0006] Furthermore, the wire insertion station and wire crimping station include paper insertion, wire insertion, and wire crimping devices. The stator core to be assembled is transported to the paper insertion, wire insertion, and wire crimping devices through a conveyor line, and then the bent insulating paper and wire type a, wire type b, wire type c, and wire type d are respectively inserted into the stator core through the paper insertion, wire insertion, and wire crimping devices. After the insertion is completed, the flat copper wire is pressed into place to ensure that the distance between the end face of the copper wire at the outlet end and the surface of the core meets the theoretical requirements; after the pressing is completed, the stator core with the pressed copper wire is transferred to the expansion station.

[0007] Furthermore, the paper inserting, wire inserting and wire pressing device also includes a back-leaning mechanism, which is used to support the welding end of the flat copper wire and move synchronously with the wire pressing servo. The crown end copper wire is fixed in an inner support and outer embrace manner to clamp it. The pressure head descends to the limit column and rests against the surface of the stator core e to ensure that the end face of the copper wire welding end is at a height that meets theoretical requirements from the core surface.

[0008] Furthermore, the expanding station includes a expanding device. During expanding, the position of the expanding head of the expanding device is ensured to be in the upper middle area of ​​the copper wire height from the surface of the stator core to ensure that the copper wire has a natural shape after twisting and the wire feet do not self-twist. After the copper wire expansion is completed, the stator is transferred to the twisting station.

[0009] Furthermore, the twisting station includes a twisting device for twisting the expanded copper wire. A spinning one-time forming process is used for twisting the copper wire into place, and the U-shaped wire is twisted into corresponding line type a, line type b, line type c, and line type d, and the welding overlap position is accurate; wherein the width of the twisting die slot is greater than the copper wire width, thereby increasing the depth of the copper wire foot entering the die. The deeper the die is, the closer the force point on the copper wire is to the bending point during twisting, which is beneficial to improving the twisting forming quality of the copper wire; wherein the depth of entry into the die is determined as long as it is ensured that the wire foot can escape from the twisting die without interference during the rotation process; after the twisting is completed, the stator is transferred to the welding station.

[0010] Furthermore, the welding station includes a welding device, and a single-mode laser is used during welding to perform depth welding at the lap joints of the copper wire legs to form a molten pool shape; the welding tooling used during welding adopts an integrated single-slot independent clamping method to ensure that the two copper wires at each welding point are tightly fitted without gaps and light leakage; after the copper wire welding is completed, the stator is transferred to the electrical testing station for electrical testing operations.

[0011] Furthermore, the electrical testing station includes an electrical testing device, and the welded copper wires are connected to the copper wires through connecting wires, so as to perform point testing on the welding points of the copper wires to ensure that each welding point is energized; after the inspection is completed, the motor stator is transferred to the paint dripping station.

[0012] Furthermore, the paint dripping station includes a paint dripping device. After the welded iron core is tested and qualified, the paint dripping operation is performed on the welding points of the copper wire at the paint dripping device, and after the paint dripping is completed, the paint dripping operation is transferred to the coating station.

[0013] Furthermore, the coating station includes a coating device for coating the drip paint of the copper wire welding point with insulation treatment so that the copper wire after welding has sufficient insulation. After the coating is completed, the motor stator is transferred to the electrical testing station for assembly electrical performance testing to ensure that the copper wire winding after the insulation coating has sufficient insulation. After passing the test, the stator assembly is completed.

[0014] Compared with the prior art, the present invention has the following beneficial effects:

[0015] The production process provided by the present invention eliminates the need for a cutting station to cut the copper wire, thereby saving equipment costs and reducing copper wire losses, thereby effectively saving production costs, thereby making the produced X-Pin stator have excellent performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 Schematic diagram of the process flow;

[0017] Figure 2 Provide a schematic diagram of the production equipment layout;

[0018] Figure 3 Schematic diagram of stator core;

[0019] Figure 4 It is a line diagram;

[0020] Figure 5 It is a schematic diagram of a straight flat copper wire after being cut;

[0021] Figure 6 Cutter position and cutting diagram;

[0022] Figure 7 It is a schematic diagram of press assembly;

[0023] Figure 8 This is a schematic diagram of copper wire welding;

[0024] In the figure: wire forming station-1, flat copper wire straightening, paint removal, cutting device-11, wire forming device-12, paper inserting station-2, insulating paper forming device-21, wire inserting station-3, paper inserting, wire inserting, wire pressing device-31, wire pressing station-4, back-leaning mechanism-41, expansion station-5, expansion device-51, head twisting station-6, head twisting device-61, welding station-7, welding device-71, electrical testing station-8, electrical testing device-81, paint dripping station-9, paint dripping device-91, coating station-10, coating device-101, wire type a, wire type b, wire type c, wire type d, stator core e, copper wire winding f. DETAILED DESCRIPTION

[0025] In order to enable those skilled in the art to better understand the technical solutions of the present invention, the technical solutions in the embodiments of the present invention are clearly and completely described below in conjunction with the accompanying drawings and specific embodiments.

[0026] Please refer to Figure 1-8 , Figure 1 Schematic diagram of the process flow; Figure 2 Provide a schematic diagram of the production equipment layout; Figure 3 Schematic diagram of stator core; Figure 4 It is a line diagram; Figure 5 It is a schematic diagram of a straight flat copper wire after being cut; Figure 6 Cutter position and cutting diagram; Figure 7 It is a schematic diagram of press assembly; Figure 8 Schematic diagram of copper wire welding.

[0027] An X-Pin stator includes a stator core e and a copper wire winding f inserted inside the stator core e, wherein the copper wire winding f includes a crown end and a welding end, and the copper wire winding f is mainly formed by winding multiple layers of flat copper wires. During the assembly process, the flat copper wires need to be bent into U-shaped wires by 2D and 3D in advance, and then the U-shaped wires are inserted inside the stator core e. After the insertion is completed, the welding ends of the U-shaped wires are expanded, twisted, clamped, and welded into one piece through tooling, and then the The welding points are coated with paint so that the copper wire winding f meets the use requirements; the bending line types of the copper wire include multiple line types a, line type b, line type c, and line type d; the outer diameter of the stator core e is 224mm, the inner diameter of the stator core e is 157.5mm, the height of the stator core e is 86mm, the number of slots of the stator core e is 72 slots, the crown end height of the stator winding f is 27.25mm, the welding end height is 30mm, and the copper wire torsion angle is 25°.

[0028] The present invention provides an X-Pin stator production process and method for the assembly production of the X-Pin stator. The complete production process flow includes, from front to back, a wire forming station 1, a paper inserting station 2, a wire inserting station 3, a wire pressing station 4, a flaring station 5, a head twisting station 6, a welding station 7, an electrical testing station 8, a paint dripping station 9, and a coating station 10.

[0029] The wire forming station 1 is provided with a flat copper wire straightening, paint removal, cutting device 11 and a wire forming device 12, which are respectively used for the straightening, paint removal, cutting and forming of the flat copper wire; at the flat copper wire straightening, paint removal and cutting device 11, the flat copper wire is first straightened, and then the corresponding wire foot shape and the length of the flat copper wire to be cut are determined according to the shapes of the wire type a, wire type b, wire type c and wire type d, and after the determination is completed, the corresponding cutter position is determined on the straightened flat copper wire and the corresponding cutter structure is designed, and the flat copper wire at the corresponding position is paint removed, and after paint removal, the flat copper wire is cut at the cutter position accordingly, and the flat copper wire is cut into multiple sections of straight flat copper wire that need to be bent, and the wire foot is cut into an inclined surface or an arc surface when the copper wire is cut; then the straight flat copper wire is transferred to the wire forming device 12 and then the straight flat copper wire after cutting is subjected to 2D and 3D mold stamping to produce a U-shaped wire.

[0030] The paper insertion station 2 includes an insulating paper forming device 21, which is used to roll, cut and shape the insulating paper and perform corresponding bending operations. The bent insulating paper is transferred to the wire insertion station 3.

[0031] The wire insertion station 3 and the wire crimping station 4 include a paper insertion, wire insertion, and wire crimping device 31. The stator core to be assembled is transported to the paper insertion, wire insertion, and wire crimping device 31 through a conveyor line, and then the bent insulating paper and wire types a, b, c, and d are respectively inserted into the stator core through the paper insertion, wire insertion, and wire crimping device 31. After the insertion is completed, the flat copper wire is pressed into place to ensure that the distance between the end face of the copper wire at the outlet end and the surface of the core meets the theoretical requirements; after the pressing is completed, the stator core with the pressed copper wire is transferred to the expansion station 5.

[0032] When crimping the wire, the back-rest mechanism 41 is used to support the end face of the copper wire and move synchronously with the wire crimping servo. The crown-end copper wire is fixed by inner support and outer embrace to clamp it. The pressure head 42 descends until the limit column 43 rests against the surface of the stator core e to ensure that the end face of the copper wire welding end is at a height that meets the theoretical requirements from the core surface.

[0033] The expanding station 5 includes a expanding device 51. During expanding, the position of the expanding head of the expanding device 51 from the surface of the stator core should be ensured to be in the upper middle area of ​​the copper wire height to ensure that the copper wire has a natural shape after twisting and the wire feet do not self-twist. After the copper wire is expanded, it is transferred to the twisting station 6.

[0034] The twisting station 6 includes a twisting device 61, which is used to twist the expanded copper wire. When twisting, a spinning one-step forming process is used to twist the copper wire into place, and the U-shaped wire is twisted into corresponding line type a, line type b, line type c, and line type d, and the welding overlap position is accurate; wherein the width of the twisting die slot is as large as possible from the copper wire width, thereby increasing the depth of the copper wire foot entering the mold. The deeper the mold is, the closer the force point to the bending point is when twisting, which is beneficial to improving the twisting forming quality of the copper wire. The determination of the mold depth only requires that the wire foot can escape from the twisting die without interference during the rotation process; after the twisting is completed, the stator is transferred to the welding station 7.

[0035] The welding station 7 includes a welding device 71. A single-mode laser is used during welding to perform a depth-direction welder at the overlap of the copper wire foot to form a molten pool shape without forming a sphere on the welding surface. This welding method has a small heat-affected zone and will not burn the paint film. If the previous process cannot well ensure the distance between the copper wire at the welding end and the surface of the iron core, it will directly manifest itself in the welding station as under-lapping and over-lapping of the welding overlap surface, resulting in a smaller welding area, otherwise there will be a risk of light leakage and paint burns; the welding tooling used during welding adopts an integrated single-slot independent clamping method to ensure that the two copper wires at each welding point are tightly fitted without gaps and no light leakage. After the copper wire welding is completed, the stator is transferred to the electrical testing station 8 for electrical testing. The electrical testing station 8 includes an electrical testing device 81. The welded copper wire is connected to the copper wire through a connecting wire, so that the welding point of the copper wire is tested to ensure that each welding point is energized. After the inspection is completed, the motor stator is transferred to the paint dripping station 9.

[0036] The paint dripping station 9 includes a paint dripping device 91. After the welded iron core is tested and qualified, the paint dripping operation is performed on the welding points of the copper wire at the paint dripping device 91. After the paint dripping is completed, the paint dripping operation is transferred to the coating station 10.

[0037] The coating station 10 includes a coating device 101, which is used to coat the drip paint of the copper wire welding point with insulation so that the copper wire after welding has sufficient insulation. After the coating is completed, the motor stator is transferred to the electrical testing station 8 for assembly electrical performance testing to ensure that the copper wire winding after the insulation coating has sufficient insulation. After passing the test, the stator assembly is completed.

[0038] The production process provided by the present invention eliminates the need for a cutting station to cut the copper wire, thereby saving equipment costs and reducing copper wire losses, thereby effectively saving production costs, thereby making the produced X-Pin stator have excellent performance.

[0039] Although the embodiments of the present invention have been shown and described, it is obvious that the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, it can be understood by ordinary technicians in this field that all other embodiments obtained by making various changes, modifications, substitutions and variations to these embodiments without departing from the principles and spirit of the present invention and without making creative work, all belong to the scope of protection of the present invention.

Claims

1. A production process and method for an X-Pin stator, the X-Pin stator comprising a stator core e and a copper wire winding f, the copper wire winding f being mainly formed by winding multiple layers of flat copper wires, including a crown end and a welding end, and the bending line type of the copper wire comprising a plurality of line types a, b, c, and d; the outer diameter of the stator core e is 224 mm, the inner diameter of the stator core e is 157.5 mm, the height of the stator core e is 86 mm, the number of slots of the stator core e is 72, the crown end height of the stator winding f is 27.25 mm, the welding end height is 30 mm, and the copper wire torsion angle is 25°; characterized in that: The production process comprises, from front to back, a wire forming station (1), a paper inserting station (2), a wire inserting station (3), a wire pressing station (4), a flaring station (5), a head twisting station (6), a welding station (7), an electrical testing station (8), a paint dripping station (9), and a coating station (10).

2. The X-Pin stator production process and method according to claim 1, characterized in that: The wire forming station (1) is provided with a flat copper wire straightening, paint stripping and cutting device (11) and a wire forming device (12). At the flat copper wire straightening, paint stripping and cutting device (11), the flat copper wire is firstly straightened, and then the corresponding wire foot shape and the length of the flat copper wire to be cut are determined according to the shapes of the wire type a, the wire type b, the wire type c and the wire type d. After the determination is completed, the corresponding cutting knife position is determined on the straightened flat copper wire and the corresponding cutting knife structure is designed, and the flat copper wire at the corresponding position is subjected to paint stripping. After the paint is removed, the flat copper wire is cut into multiple sections of straight flat copper wire at the cutter position, and the wire legs are cut into bevels or arcs while the copper wire is cut; the straight flat copper wire is then transferred to a wire forming device (12) for 2D and 3D die stamping to produce a U-shaped wire; the paper insertion station (2) includes an insulating paper forming device (21) for rolling, cutting and forming the insulating paper and performing corresponding bending operations, and the bent insulating paper is transferred to the wire insertion station (3).

3. The X-Pin stator production process and method according to claim 2, characterized in that: The wire insertion station (3) and the wire pressing station (4) comprise a paper insertion, wire insertion and wire pressing device (31). The stator core to be assembled is transported to the paper insertion, wire insertion and wire pressing device (31) via a conveyor line. Then, the bent insulating paper and the wire type a, wire type b, wire type c and wire type d are respectively inserted into the stator core via the paper insertion, wire insertion and wire pressing device (31). After the insertion is completed, the flat copper wire is pressed into place to ensure that the distance between the end face of the copper wire at the outlet end and the surface of the core meets the theoretical requirements. After the pressing is completed, the stator core with the copper wire pressed is transferred to the expansion station (5).

4. The X-Pin stator production process and method according to claim 3, characterized in that: The paper inserting, wire inserting and wire pressing device (31) further comprises a back-resting mechanism (41), which is used to support the welding end of the flat copper wire and move synchronously with the wire pressing servo. The crown end copper wire is fixed in an inner supporting and outer holding manner to be clamped. The pressure head (42) is lowered to the limit column (43) to press against the surface of the stator core e, ensuring that the height of the end face of the copper wire welding end from the core surface meets the theoretical requirement.

5. The X-Pin stator production process and method according to claim 4, characterized in that: The expanding station (5) comprises an expanding device (51). During the expanding process, the expanding head of the expanding device (51) is located at a position in the upper middle area of ​​the copper wire height from the surface of the stator core, so as to ensure that the copper wire has a natural shape after the twisting and that the wire feet do not self-twist. After the copper wire expansion is completed, the stator is transferred to the twisting station (6).

6. The X-Pin stator production process and method according to claim 5, characterized in that: The twisting station (6) includes a twisting device (61) for twisting the expanded copper wire. The twisting process is performed by a one-step spinning forming process to twist the copper wire into place, twist the U-shaped wire into corresponding wire types a, b, c, and d, and ensure accurate welding overlap positions. The width of the twisting die slot is greater than the width of the copper wire, thereby increasing the depth of the copper wire foot entering the die. The deeper the die is, the closer the force point to the bending point is when twisting, which is beneficial to improving the twisting forming quality of the copper wire. The depth of the die is determined as long as it is ensured that the wire foot can escape from the twisting die without interference during the rotation process. After the twisting is completed, the stator is transferred to the welding station (7).

7. The X-Pin stator production process and method according to claim 6, characterized in that: The welding station (7) comprises a welding device (71). A single-mode laser is used during welding to perform a depth-direction welding at the overlapped seams of the copper wire legs to form a molten pool shape. The welding tooling used during welding adopts an integrated single-slot independent clamping method to ensure that the two copper wires at each welding point are tightly fitted without gaps and light leakage. After the copper wire welding is completed, the stator is transferred to the electrical testing station (8) for electrical testing.

8. The X-Pin stator production process and method according to claim 7, characterized in that: The electrical testing station (8) comprises an electrical testing device (81), and the welded copper wires are connected to the copper wires via connecting wires, so as to perform point testing on the welding points of the copper wires to ensure that each welding point is energized; after the test is completed, the motor stator is transferred to the paint dripping station (9).

9. The X-Pin stator production process and method according to claim 8, characterized in that: The paint dripping station (9) comprises a paint dripping device (91). After the welded iron core is tested and found to be qualified, the paint dripping operation is performed on the welding points of the copper wire at the paint dripping device (91). After the paint dripping is completed, the paint dripping operation is transferred to the coating station (10).

10. The X-Pin stator production process and method according to claim 9, characterized in that: The coating station (10) comprises a coating device (101) for coating the drip paint of the copper wire welding point with insulation treatment, so that the copper wire after welding has sufficient insulation. After the coating is completed, the motor stator is transferred to the electrical testing station (8) to perform an assembly electrical performance test to ensure that the copper wire winding after the insulation coating has sufficient insulation. After passing the test, the stator assembly is completed.

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