An x-pin stator production process and method

Abstract

The application discloses an X-Pin stator production process and method, relates to the technical field of flat wire motor stator production, and comprises a wire forming station, a paper inserting station, a wire inserting station, a wire pressing station, an expanding station, a head twisting station, a welding station, an electric testing station, a paint dripping station and a coating station. The production process route provided by the application omits the head cutting station, so that the copper wire is not subjected to head cutting operation, the device cost is saved, the copper wire loss is reduced, the production cost is effectively saved, and thus the produced X-Pin stator has excellent performance.

Description

Technical Field

[0001] This invention relates to the field of flat wire motor stator manufacturing technology, specifically to an X-Pin stator manufacturing process and method. Background Technology

[0002] Existing flat wire motors have a straight section of about 10mm at the welded end. Removing this section to reduce the size of the copper wire end can decrease copper loss, improve efficiency, and reduce the motor's size. Because the copper wire overlap forms an X-shape, it is called an X-Pin stator. Due to these advantages, major stator manufacturers are actively launching X-Pin stator products. However, because the X-Pin stator eliminates the straight section, existing production processes and equipment have very little operating space for clamping the stator copper wire, which cannot meet production requirements. This makes the manufacturing of X-Pin stators difficult, necessitating a completely new production process and method. Summary of the Invention

[0003] The purpose of this invention is to provide an X-Pin stator manufacturing process and method to solve the problems mentioned in the background art, such as the high manufacturing difficulty of X-Pin stators and the inability of existing manufacturing processes and equipment to meet production requirements.

[0004] To achieve the above objectives, the present invention provides the following technical solution: an X-Pin stator manufacturing process and method, wherein the X-Pin stator includes a stator core e and a copper wire winding f, the main body of the copper wire winding f is composed of multi-layer flat copper wire winding, including a crown end and a welding end, and the bending wire shape of the copper wire includes multiple wire shapes a, b, c, and 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, the height of the crown end of the stator winding f is 27.25mm, the height of the welding end is 30mm, and the copper wire twist angle is 25°; the manufacturing process includes, from front to back, the following steps: wire forming station, paper insertion station, wire insertion station, wire pressing station, flaring station, twisting station, welding station, electrical testing station, paint dripping station, and coating station.

[0005] Furthermore, the wire forming station is equipped with a flat copper wire straightening, paint removal, and cutting device, as well as a wire forming device. At the flat copper wire straightening, paint removal, and cutting device, the flat copper wire is first straightened. Then, based on the shapes of wire types a, b, c, and d, the corresponding lead shape and the length of flat copper wire to be cut are determined. After determination, the corresponding cutting position and corresponding cutting structure are determined on the straightened flat copper wire, and the paint is removed from the flat copper wire at the corresponding position. After paint removal, the flat copper wire is cut into multiple straight flat copper wire segments at the cutting position. At the same time, the lead is cut into bevels or arcs. Then, the straight flat copper wire is transferred to the wire forming device for 2D and 3D mold stamping to form U-shaped wires. The paper insertion station includes an insulating paper forming device, which is used to roll, cut, and bend the insulating paper. The bent insulating paper is then transferred to the wire insertion station.

[0006] Furthermore, the insertion station and pressing station include paper insertion, wire insertion, and pressing devices. The stator core to be assembled is conveyed to the paper insertion, wire insertion, and pressing devices via a conveyor line. Then, the bent insulating paper and wire types a, b, c, and d are inserted into the stator core through the paper insertion, wire insertion, and pressing devices. After insertion, the flat copper wire is pressed into place to ensure that the distance between the copper wire end face and the core surface meets the theoretical requirements. After pressing, the stator core with the pressed copper wire is transferred to the flaring station.

[0007] Furthermore, the paper insertion, wire insertion, and wire pressing device also includes a reverse support mechanism. The reverse support mechanism supports the welding end of the flat copper wire and moves synchronously with the wire pressing servo. The copper wire at the crown end is fixed by an internal support and external clamping method to clamp it. The pressing head descends to the top of the limit post and touches the surface of the stator core e, ensuring that the height of the end face of the copper wire welding end from the surface of the core meets the theoretical requirements.

[0008] Furthermore, the flaring station includes a flaring device. During flaring, the distance between the flaring head and the surface of the stator core is maintained in the upper-middle range of the copper wire height to ensure that the copper wire has a natural shape after twisting and that the wire leads do not self-twist. After the copper wire flaring is completed, the stator is transferred to the twisting station.

[0009] Furthermore, the twisting station includes a twisting device for twisting the flared copper wire. The twisting process employs a one-step spinning process to twist the copper wire into the correct position, transforming the U-shaped wire into corresponding wire types a, b, c, and d, while ensuring accurate welding overlap. The width of the twisting die slot is greater than the width of the copper wire, thereby increasing the depth of the copper wire lead into the die. A deeper die entry means the force application point during twisting is closer to the bending point, which improves the quality of the copper wire twisting. The depth of entry is determined by ensuring that the lead can exit the twisting die without interference during rotation. After twisting, the stator is transferred to the welding station.

[0010] Furthermore, the welding station includes a welding device. During welding, a single-mode laser is used to perform depth welding at the overlap of the copper wire leads to form a molten pool. The welding fixture used during welding adopts an integrated single-slot independent clamping method to ensure that the two copper wires at each weld point are tightly attached without gaps and to prevent light leakage. After the copper wire welding is completed, the stator is transferred to the electrical testing station for electrical testing.

[0011] Furthermore, the electrical testing station includes an electrical testing device. The welded copper wire is connected to the copper wire via a connecting wire, thereby performing point testing on the welded points of the copper wire to ensure that each welded point is energized. After the test is completed, the motor stator is transferred to the paint dripping station.

[0012] Furthermore, the paint-drip station includes a paint-drip device. After the welded iron core passes inspection, paint-drip operations are performed on the copper wire solder joints at the paint-drip device. After the paint-drip is completed, the core is transferred to the coating station.

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

[0014] Compared with the prior art, the beneficial effects of the present invention are:

[0015] The production process provided by this invention eliminates the need for a cutting station to cut the copper wire, saving equipment costs and reducing copper wire loss, thus effectively reducing production costs and resulting in X-Pin stators with excellent performance. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the process flow;

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

[0018] Figure 3 This is a schematic diagram of the stator core.

[0019] Figure 4 This is a schematic diagram of the line type;

[0020] Figure 5 This is a schematic diagram of the cut straight flat copper wire;

[0021] Figure 6 Cutting blade position and cutting diagram;

[0022] Figure 7 This is a schematic diagram of the press-fitting process;

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

[0024] In the diagram: Wire forming station-1, flat copper wire straightening, paint removal, cutting device-11, wire forming device-12, paper insertion station-2, insulating paper forming device-21, wire insertion station-3, paper insertion, wire insertion, wire pressing device-31, wire pressing station-4, reverse mechanism-41, flaring station-5, flaring device-51, twisting station-6, 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 Implementation

[0025] 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 will be clearly and completely described below in conjunction with the accompanying drawings and specific embodiments.

[0026] Please refer to Figures 1-8 , Figure 1 This is a schematic diagram of the process flow; Figure 2 A schematic diagram of the production equipment layout; Figure 3 This is a schematic diagram of the stator core. Figure 4 This is a schematic diagram of the line type; Figure 5 This is a schematic diagram of the cut straight flat copper wire; Figure 6 Cutting blade position and cutting diagram; Figure 7 This is a schematic diagram of the press-fitting process; Figure 8 This is a 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. The copper wire winding f includes a crown end and a welded end. The main body of the copper wire winding f is made of multi-layer flat copper wire winding. During assembly, the flat copper wire needs to be bent into a U-shape by 2D and 3D beforehand. Then, the U-shaped wire is inserted into the stator core e. After insertion, the welded end of the U-shaped wire is flared, twisted, clamped, and welded together using tooling. The solder joints are coated with varnish to ensure that the copper wire winding f meets the usage requirements; the copper wire bending profiles include multiple profiles a, b, c, and d; the stator core e has an outer diameter of 224 mm, an inner diameter of 157.5 mm, a height of 86 mm, and 72 slots; the height of the crown end of the stator winding f is 27.25 mm, the height of the weld end is 30 mm, and the copper wire twist angle is 25°.

[0028] This invention provides an X-Pin stator manufacturing process and method for use in the assembly and production of X-Pin stators. The complete production process flow includes, from front to back, the following steps: wire forming station 1, paper insertion station 2, wire insertion station 3, wire pressing station 4, flaring station 5, twisting station 6, welding station 7, electrical testing station 8, paint dripping station 9, and coating station 10.

[0029] The wire forming station 1 is equipped with a flat copper wire straightening, paint removal, and cutting device 11 and a wire forming device 12, which are used for straightening, paint removal, cutting, and forming operations of flat copper wire, respectively. At the flat copper wire straightening, paint removal, and cutting device 11, the flat copper wire is first straightened. Then, according to the shape of wire type a, wire type b, wire type c, and wire type d, the corresponding wire lead shape and the length of flat copper wire to be cut are determined. After the determination is completed, the corresponding cutting position is determined on the straightened flat copper wire and the corresponding cutting structure is designed. The flat copper wire at the corresponding position is then painted. After the paint is removed, the flat copper wire is cut at the cutting position to cut it into multiple straight flat copper wires that need to be bent. At the same time as the copper wire is cut, the wire leads are cut into bevels or arcs. Then, the straight flat copper wires are transferred to the wire forming device 12, and the cut straight flat copper wires are then stamped into U-shaped wires using 2D and 3D molds.

[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 then transferred to the wire insertion station 3.

[0031] The insertion station 3 and pressing station 4 include paper insertion, wire insertion, and pressing devices 31. The stator core to be assembled is conveyed to the paper insertion, wire insertion, and pressing device 31 via a conveyor line. Then, the bent insulating paper and wire types a, b, c, and d are inserted into the stator core through the paper insertion, wire insertion, and pressing device 31. After insertion, the flat copper wire is pressed into place to ensure that the distance between the copper wire end face and the core surface meets the theoretical requirements. After pressing, the stator core with the pressed copper wire is transferred to the flaring station 5.

[0032] During the wire pressing process, the anti-copper wire end face is supported by the anti-copper mechanism 41 and moves synchronously with the wire pressing servo. The copper wire at the crown end is fixed by an internal support and external clamping method to clamp it. The pressing head 42 descends to the limit post 43 and touches the surface of the stator core e to ensure that the height of the end face of the copper wire welding end from the surface of the core meets the theoretical requirements.

[0033] The flaring station 5 includes a flaring device 51. During flaring, the distance between the flaring head of the flaring device 51 and the surface of the stator core should be in the upper-middle range of the copper wire height to ensure that the copper wire has a natural shape after twisting and that the wire leads do not twist. After the copper wire is flared, it is transferred to the twisting station 6.

[0034] The twisting station 6 includes a twisting device 61 for twisting the flared copper wire. The twisting process employs a one-step spinning process to twist the copper wire into the correct position, transforming the U-shaped wire into corresponding wire types a, b, c, and d, while ensuring accurate welding overlap. The width of the twisting die slot is as large as possible compared to the width of the copper wire, thereby increasing the depth of the copper wire lead into the die. A deeper die entry means the force application point during twisting is closer to the bending point, which improves the quality of the twisted copper wire forming. The depth of entry is determined by ensuring that the lead can exit the twisting die without interference during rotation. After twisting, the stator is transferred to the welding station 7.

[0035] The welding station 7 includes a welding device 71. During welding, a single-mode laser is used to perform depth-direction welding at the copper wire lead overlap, forming a molten pool shape instead of a spherical shape on the weld surface. This welding method results in a small heat-affected zone and avoids burning the paint film. If the preceding process cannot adequately ensure the distance between the copper wire at the welding end and the iron core surface, this will directly manifest as under-lap or over-lap at the welding station, leading to a smaller welding area and the risk of light leakage and paint burn. The welding fixture used during welding employs an integrated single-slot independent clamping method to ensure that the two copper wires at each weld point are tightly fitted without gaps, preventing 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 wires are connected to each other via connecting wires to perform point testing on the weld points, ensuring that each weld point is energized. After testing, 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 passes inspection, paint dripping is performed on the copper wire solder joints at the paint dripping device 91. After the paint dripping is completed, the core is transferred to the coating station 10.

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

[0038] The production process provided by this invention eliminates the need for a cutting station to cut the copper wire, saving equipment costs and reducing copper wire loss, thus effectively reducing production costs and resulting in X-Pin stators with excellent performance.

[0039] Although 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, and not all of the embodiments. Based on the embodiments of the present invention, it will be understood by those skilled in the art 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 creative effort are within the scope of protection of the present invention.

Claims

1. A method for producing an X-Pin stator, wherein the X-Pin stator comprises a stator core e and a copper wire winding f, the copper wire winding f being mainly composed of multi-layer flat copper wire windings, including a crown end and a welded end, and the bending profile of the copper wire including multiple wire types a, b, c, and d; the stator core e has an outer diameter of 224 mm, an inner diameter of 157.5 mm, a height of 86 mm, and 72 slots; the crown end height of the copper wire winding f is 27.25 mm, the welded end height is 30 mm, and the copper wire twist angle is 25°; characterized in that: The production method includes, from front to back, the following steps: wire forming station (1), paper insertion station (2), wire insertion station (3), wire pressing station (4), flaring station (5), twisting station (6), welding station (7), electrical testing station (8), paint dripping station (9), and coating station (10). The wire forming station (1) is equipped with a flat copper wire straightening, paint removal, and cutting device (11) and a wire forming device (12). At the flat copper wire straightening, paint removal, and cutting device (11), the flat copper wire is first straightened, and then the corresponding lead 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 confirmation, determine the corresponding cutting position and design the corresponding cutting structure on the straightened flat copper wire, and perform paint removal on the flat copper wire at the corresponding position. After paint removal, cut the flat copper wire at the cutting position to cut it into multiple straight flat copper wires. At the same time as cutting the copper wire, cut the wire feet into bevels or arcs. Then transfer the straight flat copper wires to the wire forming device (12) for 2D and 3D mold stamping to make U-shaped wires. 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. The bent insulating paper is transferred to the wire insertion station. Position (3); The insertion station (3) and the pressing station (4) include paper insertion, wire insertion, and pressing device (31). The stator core to be assembled is conveyed to the paper insertion, wire insertion, and pressing device (31) via the conveyor line. Then, the bent insulating paper and wire types a, b, c, and d are inserted into the stator core by the paper insertion, wire insertion, and pressing device (31). After insertion, the flat copper wire is pressed into place to ensure that the distance between the copper wire end face and the core surface meets the theoretical requirements. After pressing, the stator core with the pressed copper wire is transferred to the flaring station (5). The paper insertion, wire insertion, and pressing device (31) also includes a reverse pressing machine. The structure (41) uses a reverse support mechanism (41) to support the welding end of the flat copper wire and moves synchronously with the wire pressing servo. The copper wire at the crown end is fixed by an inner support and outer hug, and the pressing head (42) descends to the limit post (43) and touches the surface of the stator core e, ensuring that the end face of the copper wire welding end is at a height that meets the theoretical requirements from the surface of the core. The flaring station (5) includes a flaring device (51). When flaring, the position of the flaring head of the flaring device (51) from the surface of the stator core is ensured to be in the middle and upper region of the copper wire height, so as to ensure that the copper wire shape is natural after twisting and the wire leg does not twist. After the copper wire is flared, the stator is transferred to the twisting station (6).

2. The X-Pin stator manufacturing method according to claim 1, characterized in that: The twisting station (6) includes a twisting device (61) for twisting the copper wire that has been flared. The twisting process uses a one-time spinning forming process to twist the copper wire into the correct position, twisting the U-shaped wire into the corresponding wire type a, wire type b, wire type c, and wire type d, and ensuring that the welding overlap position is accurate. The width of the twisting mold slot is greater than the width of the copper wire, thereby increasing the depth of the copper wire lead into the mold. The deeper the lead into the mold, the closer the force point of the copper wire is to the bending point during twisting, which is beneficial to improving the quality of the copper wire twisting and forming. The depth of the lead into the mold is determined by ensuring that the lead can come out of the twisting mold without interference during the rotation process. After the twisting is completed, the stator is transferred to the welding station (7).

3. The X-Pin stator manufacturing method according to claim 2, characterized in that: The welding station (7) includes a welding device (71). A single-mode laser is used for welding to perform depth welding at the lap joint of the copper wires to form a molten pool. The welding fixture used during welding adopts an integrated single-slot independent clamping method to ensure that the two copper wires at each weld point are tightly attached without gaps and there will be no light leakage. After the copper wire welding is completed, the stator is transferred to the electrical testing station (8) for electrical testing.

4. The X-Pin stator manufacturing method according to claim 3, characterized in that: The electrical testing station (8) includes an electrical testing device (81) to perform point testing on the copper wire welding points to ensure that each welding point is energized; after the test is completed, the motor stator is transferred to the paint dripping station (9).

5. The X-Pin stator manufacturing method according to claim 4, characterized in that: The paint dripping station (9) includes a paint dripping device (91). After the iron core is welded and passes inspection, paint dripping is performed on the copper wire solder joints at the paint dripping device (91). After the paint dripping is completed, the copper wire is transferred to the coating station (10).

6. The X-Pin stator manufacturing method according to claim 5, characterized in that: The coating station (10) includes a coating device (101) for coating the copper wire solder joints with insulating material so that the welded copper wire has sufficient insulation. After coating, the motor stator is transferred to the electrical testing station (8) for assembly electrical performance testing to ensure that the copper wire winding after coating has sufficient insulation. After passing the test, the stator assembly is completed.

Images