A method and device for producing motor coil

Abstract

The invention discloses a method and device for producing motor coils, comprising designing size data of a single coil according to the specifications and performance requirements of the motor, providing a conductor material, winding the single coil according to the size data, screening qualified single coils, placing the qualified single coils in groups of six into an automated lamination tooling for flattening, using a rolling machine to roll the flattened coil group to form a cylindrical coil cup, detecting the deviation of the coil cup and shaping it, using a high-temperature insulating material for sealing and curing to obtain an insulated motor coil; by designing the coil size, preparing and detecting a single coil with good consistency, and then obtaining a flattened coil group with enhanced structural integrity by lamination, real-time monitoring and deviation correction to ensure the production of coil cups that meet the standards, and to produce accurate, consistent coils that are optimized for high-performance applications.

Description

Technical Field

[0001] The present invention relates to the field of motor technology, and in particular to a method and device for producing a motor coil. Background Art

[0002] With the rapid development of industrial automation and high-precision equipment, brushless motors are increasingly used in aerospace, industrial control, robotics, medical equipment, consumer electronics and other fields. Brushless motors have become the preferred drive mode for many high-end devices due to their high efficiency, low noise, long life and easy maintenance. Especially in some terminal products, higher requirements are placed on the performance of motors, requiring motors to have higher efficiency, lower temperature rise and more stable operating characteristics to enhance the user experience.

[0003] In the prior art, the production process of motor coils mainly adopts traditional winding and assembly methods. Usually, multiple single coils are wound separately first, and then these single coils are wound on the stator core in a certain arrangement to assemble into a coil assembly. When winding a single coil, due to the influence of equipment precision and human factors, the size, resistance, inductance and other parameters of the single coil are prone to deviations, resulting in poor consistency. During the assembly process, the stacking and fixing methods of the coils may also cause inaccurate positional relationships between the coils, further increasing the parameter fluctuations of the coil assembly. This production process makes it difficult to ensure the consistency of the coil assembly, which in turn affects the overall performance of the motor, manifested as reduced efficiency, increased temperature rise, unstable operation and other problems, and cannot meet the requirements of modern brushless motors for high precision and high consistency.

[0004] In view of this, it is necessary to improve the production process of motor coils in the prior art to solve the technical problems of inconsistent coil component sizes and poor performance. Summary of the invention

[0005] The purpose of the present invention is to provide a method and device for producing a motor coil to solve the above technical problems.

[0006] To achieve this object, the present invention adopts the following technical solutions: A method for producing a motor coil, comprising: According to the specifications and performance requirements of the motor, the dimension data of a single coil is designed, wherein the dimension data includes an inner diameter, an outer diameter and a height; Providing conductor materials, winding single coils according to the dimension data, and using an automated detection system to measure the width, resistance and inductance of the wound single coils to screen qualified single coils; Place six qualified single coils in a group into an automated lamination tool, wrap them tightly with high-temperature adhesive tape, and immerse them in 30% anhydrous ethanol in a vacuum environment for flattening to obtain a flattened coil group; Using a rolling machine to roll the flattened coil group to form a cylindrical coil cup, and during the rolling process, detecting the deviation of the coil cup through a real-time monitoring system, and shaping the coil cup according to the deviation data; The surface of the shaped coil cup is sealed and cured using a high-temperature insulating material to obtain an insulated motor coil.

[0007] Optionally, the size data of a single coil is designed according to the specifications and performance requirements of the motor, specifically including: Obtain the specifications and performance requirements of the designed motor, including rated power, rated speed, output torque, efficiency index, and allowable temperature rise range; Based on the specifications and performance requirements, calculate the electromagnetic design parameters of the motor and determine the required resistance value, inductance value, magnetic flux density and number of coil turns for a single coil; According to the calculated electromagnetic design parameters, the size data of the single coil is designed.

[0008] Optionally, the step of designing the size data of a single coil according to the calculated electromagnetic design parameters may further include: The designed single coil is modeled by electromagnetic simulation software, its electromagnetic characteristics under working conditions are simulated, and the working parameters of the coil's resistance loss, magnetic leakage, and temperature rise are analyzed to verify the rationality of the designed dimensional data; According to the electromagnetic simulation results, the size data of the single coil is optimized and adjusted.

[0009] Optionally, providing the conductor material, winding a single coil according to the size data, and using an automated detection system to measure the width, resistance and inductance of the wound single coil to screen a qualified single coil specifically includes: Select enameled copper wire that meets the standards as the conductor material, the wire diameter is the pre-set specification, and the insulation layer temperature resistance level is not less than 180℃; Pre-processing the conductor material, including appearance inspection and cleaning the conductor surface; According to the determined size data of the single coil, the winding parameters of the automatic winding machine are set, wherein the winding parameters include winding speed, tension control, number of turns and winding direction; Under constant temperature conditions, the automatic winding machine is used to wind a single coil. After the winding is completed, the single coil is removed from the winding machine and a shaping mold is used to shape the single coil.

[0010] Optionally, the single coil is removed from the winding machine and a shaping die is used to shape the single coil, and then the process further includes: Use the visual component of the automated inspection system to measure the width of each single coil, record the measurement data, and compare it with the designed dimension data to determine whether the dimension is within the tolerance range; The resistance and inductance of each single coil are measured by the automatic detection system, and the test current is the standard current to obtain the electrical performance data. The measured width data and electrical performance data are imported into the quality control system, and a comprehensive evaluation is performed according to the preset qualification standards to screen out qualified single coils.

[0011] Optionally, the qualified single coils are placed in groups of six in an automated lamination tool, tightly wrapped with high-temperature adhesive tape, and immersed in 30% anhydrous ethanol in a vacuum environment for flattening to obtain a flattened coil group, specifically including: The qualified single coils are taken out one by one and placed in the positioning slot of the automatic lamination tooling according to a preset arrangement, wherein each subsequent single coil partially covers a part of the area of ​​the previous single coil and is arranged in a straight line in sequence, and the covering length is 20% to 45% of the length of the adjacent single coils; Adjust the positioning device in the automatic lamination tooling to position and angle each single coil, so that six single coils are stacked in the length direction to form a coil group, and the whole is arranged straight, and high-temperature adhesive tape of a preset width is used to tightly wrap the coil group along the length direction; Place the wrapped coil assembly as a whole into the container of the vacuum impregnation device, and slowly inject a 30% by mass ethanol solution in a vacuum environment with a vacuum degree of -0.08 MPa to -0.1 MPa for 3 to 5 minutes; The soaked coil assembly is transferred to a mold of a flattening device, and a hydraulic press is used to flatten the coil assembly so that the thickness of the coil assembly reaches a predetermined size. The pressing pressure is 1.0 MPa to 1.5 MPa, and the pressing time is 1 minute to 3 minutes. After the flattening process is completed, the flattened coil group is taken out from the mold and dried naturally or at a low temperature to fully volatilize the ethanol inside the flattened coil group.

[0012] Optionally, the flattened coil group is rolled up by a rolling machine to form a cylindrical coil cup, and the deviation of the coil cup is detected by a real-time monitoring system during the rolling process, and the coil cup is shaped according to the deviation data, specifically including: Place the flattened coil group on the feeding platform of the coiling machine and adjust the initial parameters of the coiling machine, including coiling speed, coiling radius and pressure settings; The rolling machine is started to gradually roll the flattened coil group into a cylindrical coil cup through a preset guide device and a forming roller, and a uniform speed and a constant pressure are maintained during the rolling process to form a preliminary coil cup; During the coiling process, a real-time monitoring system is activated to measure the key dimensions of the outer diameter and roundness of the coil cup online to obtain deviation data. The real-time monitoring system includes a laser ranging sensor and a displacement sensor. Optionally, during the coiling process, a real-time monitoring system is enabled to measure the key dimensions of the outer diameter and roundness of the coil cup online to obtain deviation data, and then the following steps are included: Comparing the deviation data with a preset standard size, and if it is found that the size deviation of the coil cup exceeds the tolerance range, sending an adjustment instruction to the control system of the coiling machine; The rolling machine automatically adjusts the working parameters of the rolling machine according to the received adjustment instructions, including fine-tuning the reel spacing, adjusting the pressure and correcting the rolling speed; After the coiling is completed, the coil cup is taken out of the coiling machine and placed in a shaping tooling, and the coil cup is subjected to a secondary shaping process by mechanical pressure or a shaping mold.

[0013] Optionally, the surface of the shaped coil cup is sealed and cured with a high-temperature insulating material to obtain an insulated motor coil, and then the following steps are further included: The size, resistance and inductance of the insulated motor coils are tested, and the inter-turn insulation performance of the coils is tested using inter-turn insulation testing equipment to sort qualified and unqualified products.

[0014] The present invention further provides a production device for a motor coil, which is manufactured using the production method for a motor coil as described above, and the production device comprises: Design module, used to obtain the specifications and performance requirements of the motor, calculate and determine the size data of a single coil; An automatic winding machine, configured to wind a single coil of the conductor material according to the dimension data, the automatic winding machine having winding speed control, tension adjustment, turn number setting and positioning functions; The automated testing system is used to measure the width, resistance and inductance of the wound single coils and select qualified single coils; An automatic lamination tooling, configured to sequentially arrange six qualified single coils in a straight line in a partially covered manner, the tooling having a positioning device; A vacuum impregnation and flattening device, comprising a vacuum container and a hydraulic press, is used to immerse the wrapped single coil assembly into a 30% anhydrous ethanol solution under a vacuum environment, and then use the hydraulic press to flatten the coil assembly to obtain a flattened coil assembly; A rolling machine configured to roll the flattened coil group to form a cylindrical coil cup, the rolling machine comprising a guide device and a forming roller; The real-time monitoring system, including laser range finder and displacement sensor, is used to detect the key dimensions of the outer diameter and roundness of the coil cup during the coiling and shaping process, and collect real-time deviation data.

[0015] Compared with the prior art, the present invention has the following beneficial effects: according to the specifications and performance requirements of a specific motor, the dimensional data of a single coil, i.e., the inner diameter, outer diameter and height, are designed, the wire material is provided, and the single coil is wound according to the predetermined dimensional data, and the width, resistance and inductance of each wound coil are measured by an automated detection system to screen out qualified coils that meet strict standards; six qualified single coils are placed in an automated lamination tooling, tightly wrapped with high-temperature tape, and immersed in 30% anhydrous ethanol in a vacuum environment for flattening. In this way, a flattened coil group with enhanced structural integrity is obtained, and the flattened coil group is rolled using a rolling machine to form a cylindrical coil cup. During this process, the real-time monitoring system detects any deviations and makes adjustments accordingly. The surface of the formed coil cup is coated with high-temperature insulating material and then cured to obtain an insulated motor coil to complete the preparation. This solution designs the coil size, prepares and detects single coils with good consistency, and then obtains a flattened coil group with enhanced structural integrity through lamination. Real-time monitoring and deviation correction ensure the production of standard coil cups, produce precise, consistent coils optimized for high-performance applications, improve production efficiency, reduce defects, and the produced motor coils support higher motor efficiency and lower operating temperature, thereby meeting the advanced requirements of modern brushless motors. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0017] The structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification so as to facilitate understanding and reading by persons familiar with this technology. They are not used to limit the conditions under which the present invention can be implemented, and therefore have no substantive technical significance. Any structural modification, change in proportion or adjustment of size, without affecting the effects and purposes that can be achieved by the present invention, should still fall within the scope of the technical contents disclosed by the present invention.

[0018] Figure 1This is a schematic diagram of a process flow of a method for producing a motor coil according to the first embodiment of the present invention; Figure 2 The second schematic flow chart of the method for producing the motor coil of the first embodiment; Figure 3 This is the third flow chart of the method for producing the motor coil of the first embodiment. DETAILED DESCRIPTION

[0019] In order to make the purpose, features and advantages of the present invention more obvious and easy to understand, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described below are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0020] In the description of the present invention, it should be understood that the terms "upper", "lower", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention. It should be noted that when a component is considered to be "connected" to another component, it may be directly connected to the other component or there may be a centrally arranged component at the same time.

[0021] The technical solution of the present invention is further described below with reference to the accompanying drawings and through specific implementation methods.

[0022] Embodiment 1: Combination Figures 1 to 3 As shown, an embodiment of the present invention provides a method for producing a motor coil, comprising: S1, design the size data of a single coil according to the specifications and performance requirements of the motor, the size data includes inner diameter, outer diameter and height; First, the size data of a single coil is designed according to the specific specifications and performance requirements of the motor. The size data includes key parameters such as inner diameter, outer diameter and height. Through calculation and optimization design, it is ensured that the size of a single coil can meet the electromagnetic performance and installation space requirements of the motor, providing an accurate basis for subsequent production and manufacturing.

[0023] S2, provide wire materials, wind single coils according to size data, and use an automated testing system to measure the width, resistance and inductance of the wound single coils to screen qualified single coils; Provide wire materials that meet the design requirements, and wind the single coil according to the size data determined in step S1. During the winding process, use automatic winding equipment to ensure that the number of turns and arrangement of the coil are accurate. After the winding is completed, use the automated detection system to measure and detect the width, resistance and inductance of each single coil. Through screening, select qualified single coils that meet the standards for all parameters to ensure the consistency and reliability of the coil.

[0024] S3, placing six qualified single coils in a group into an automated lamination tooling, wrapping them tightly with high-temperature adhesive tape, and immersing them in 30% anhydrous ethanol in a vacuum environment for flattening to obtain a flattened coil group; The qualified single coils are arranged in groups of six in a partially overlapping manner and placed in the automated lamination tooling. The six single coils are tightly wrapped along the length of the coil group using high-temperature adhesive tape to fix the six single coils into a whole. Subsequently, the wrapped coil group is placed in a vacuum environment and immersed in a 30% by mass ethanol solution for soaking. Next, pressure is applied to the soaked coil group under vacuum conditions to flatten it, resulting in a compact flattened coil group. This process effectively eliminates the air between the coils and enhances the overall strength and stability of the coil group.

[0025] S4, using a rolling machine to roll the flattened coil group to form a cylindrical coil cup, and during the rolling process, a deviation of the coil cup is detected by a real-time monitoring system, and the coil cup is reshaped according to the deviation data; The flattened coil group is rolled up by a rolling machine to form a cylindrical coil cup. During the rolling process, the real-time monitoring system continuously detects the inner diameter, outer diameter, roundness and height of the coil cup. If the dimensional deviation exceeds the tolerance range, the control system of the rolling machine will automatically adjust the working parameters of the equipment according to the deviation data and correct the shape and size of the coil cup in real time.

[0026] S5, sealing and curing the surface of the shaped coil cup with a high-temperature insulating material to obtain an insulated motor coil.

[0027] The surface of the shaped coil cup is sealed and cured with high-temperature insulation material. After the high-temperature insulation material is evenly coated on the surface of the coil cup, it is cured at an appropriate temperature and time to make the insulation layer firmly adhere to the surface of the coil. This step improves the insulation and heat resistance of the coil, and prevents failures caused by temperature rise or electrical reasons during the operation of the motor. Finally, a high-quality motor coil with insulation treatment is obtained to meet the application requirements of high efficiency and low temperature rise of the motor.

[0028] The working principle of the present invention is as follows: according to the specifications and performance requirements of a specific motor, the dimensional data of a single coil, i.e., the inner diameter, outer diameter and height, are designed, the wire material is provided, and the single coil is wound according to the predetermined dimensional data, and the width, resistance and inductance of each wound coil are measured by an automated detection system to screen out qualified coils that meet strict standards; six qualified single coils are placed in an automated lamination tooling, tightly wrapped with high-temperature tape, and immersed in 30% anhydrous ethanol in a vacuum environment for flattening. In this way, a flattened coil group with enhanced structural integrity is obtained, and the flattened coil group is rolled using a rolling machine to form a cylindrical coil cup. During this process, the real-time monitoring system detects any deviations and makes adjustments accordingly. The surface of the formed coil cup is coated with high-temperature insulating material and then cured to obtain an insulated motor coil to complete the preparation. This solution designs the coil size, prepares and detects single coils with good consistency, and then obtains a flattened coil group with enhanced structural integrity through lamination. Real-time monitoring and deviation correction ensure the production of standard coil cups, produce precise, consistent coils optimized for high-performance applications, improve production efficiency, reduce defects, and the produced motor coils support higher motor efficiency and lower operating temperature, thereby meeting the advanced requirements of modern brushless motors.

[0029] In this embodiment, it is specifically explained that step S1 specifically includes: S11, obtaining the specifications and performance requirements of the designed motor, which include rated power, rated speed, output torque, efficiency index and allowable temperature rise range; By understanding the application scenarios and performance requirements of the motor in detail, we can ensure that the designed coil can meet the operating requirements of the motor and achieve the expected performance indicators.

[0030] S12, based on the specifications and performance requirements, calculate the electromagnetic design parameters of the motor and determine the required resistance value, inductance value, magnetic flux density and number of coil turns for a single coil; By using electromagnetic design formulas and empirical data, calculate the electrical characteristics of the coil when the motor is running, such as resistance, inductance, current density, and flux density. The purpose of this step is to ensure that the electrical performance of the coil matches the overall design of the motor.

[0031] S13, design the size data of a single coil according to the calculated electromagnetic design parameters. Factors such as the space limitation, electromagnetic performance and mechanical strength of the coil need to be considered during the design process. Through reasonable size design, ensure that the coil can meet the electromagnetic performance requirements, adapt to the structural layout of the motor, and have sufficient mechanical strength and heat dissipation capacity.

[0032] S14, modeling the designed single coil through electromagnetic simulation software, simulating its electromagnetic characteristics under working conditions, analyzing the working parameters of the coil's resistance loss, magnetic leakage, and temperature rise, so as to verify the rationality of the designed dimensional data; The designed single coil is modeled by electromagnetic simulation software to simulate its electromagnetic characteristics under working conditions. Through simulation analysis, the working parameters of the coil in terms of resistance loss, magnetic leakage, and temperature rise during operation are evaluated. The simulation results can help identify potential problems in the design, such as excessive temperature rise or magnetic saturation. The purpose of this step is to verify the rationality of the designed dimensional data and ensure that the coil can maintain good performance and reliability under actual operating conditions.

[0033] S15, based on the electromagnetic simulation results, optimize and adjust the size data of the single coil to ensure that its electromagnetic performance, thermal performance and mechanical performance meet the requirements of the motor, and finally determine the size data of the single coil to guide subsequent production and manufacturing.

[0034] In this embodiment, it is specifically described that step S2 specifically includes: S21, select standard enameled copper wire as the conductor material, the wire diameter is the preset specification, and the insulation layer temperature resistance level is not less than 180℃; The selected enameled copper wire needs to have a pre-set wire diameter specification to meet the designed single coil size requirements; and, in order to ensure that the coil has good heat resistance during operation, the insulation layer of the wire must have a temperature resistance level of no less than 180°C, which not only ensures the stable operation of the coil in a high temperature environment, but also extends the service life of the motor.

[0035] S22, pre-processing the wire material, including appearance inspection and cleaning the wire surface; at the same time, cleaning the wire surface to remove impurities such as oil, dust, etc. This pre-treatment process can improve the surface quality of the wire and ensure that the insulation layer of the wire is intact during the winding process.

[0036] S23, setting winding parameters of the automatic winding machine according to the determined size data of the single coil, the winding parameters including winding speed, tension control, number of turns and winding direction; The setting of winding speed needs to balance production efficiency and coil quality, and tension control ensures that the wire maintains appropriate tightness during the winding process to prevent looseness or over-tightness. The number of turns and winding direction directly affect the inductance value and magnetic field direction of the coil, and must be set strictly according to the design requirements. By setting the winding parameters, it is ensured that the wound single coil has consistent electrical performance and dimensional accuracy.

[0037] S24, under constant temperature conditions, use an automatic winding machine to wind a single coil. After winding, remove the single coil from the winding machine and use a shaping mold to shape the single coil to maintain the accuracy of its width, height and diameter to prevent dimensional changes due to elastic rebound.

[0038] In this embodiment, it is further explained that after step S24, the following steps are further included: S25, use the visual component of the automated inspection system to measure the width of each single coil, record the measurement data, and compare it with the designed size data to determine whether the size is within the tolerance range; if it is found that the size exceeds the tolerance range, it can be removed or adjusted in time to ensure that only coils with qualified sizes enter the next step.

[0039] S26, measuring the resistance and inductance of each single coil through an automated detection system, with the test current being a standard current, to obtain electrical performance data; Resistance and inductance are key parameters that reflect the electrical performance of the coil and have a significant impact on the performance of the motor. By accurately measuring these parameters, coils with electrical performance that meets the design requirements can be screened out, thereby improving the performance consistency of the entire motor.

[0040] S27, imports the measured width data and electrical performance data into the quality control system, conducts a comprehensive evaluation according to the preset qualification standards (size deviation ±0.02 mm, resistance and inductance deviation ±1%), and screens out qualified single coils. Based on the evaluation results, qualified single coils are screened out, and unqualified coils are marked. Through quality control, it is ensured that the coils entering the subsequent processes are of high quality and high consistency.

[0041] In this embodiment, it is specifically described that step S3 specifically includes: S31, taking out qualified single coils one by one, and placing them in the positioning slots of the automatic lamination tooling according to a preset arrangement, wherein each subsequent single coil partially covers a portion of the previous single coil, and they are arranged in a straight line in sequence, and the covering length is 20% to 45% of the length of the adjacent single coils; The qualified single coils are taken out one by one and placed in the positioning slot of the automatic lamination tooling according to the preset arrangement. The arrangement is that each subsequent single coil partially covers part of the area of ​​the previous single coil, and is arranged in a straight line. Specifically, the covering length of adjacent single coils is 20% to 45% of the length of the previous single coil. This partially overlapping arrangement can enhance the overall structural strength of the coil group, ensure the continuity of current conduction, and help the stability of the coil group in subsequent processing.

[0042] S32, adjust the positioning device in the automated lamination tooling to locate the position and angle of each single coil, so that the six single coils are stacked in the length direction to form a coil group, and the overall arrangement is straight, and use high-temperature tape of a preset width to tightly wrap the coil group along the length direction; fix the six single coils into one, and ensure that the tape is flat and wrinkle-free when wrapping, and leave appropriate length at both ends for subsequent processing.

[0043] S33, placing the wrapped coil group as a whole into the container of the vacuum impregnation device, and slowly injecting a 30% by mass anhydrous ethanol solution under a vacuum environment with a vacuum degree of -0.08 MPa to -0.1 MPa for a soaking time of 3 to 5 minutes to remove the air inside the coil and improve the wettability between the coils.

[0044] S34, transferring the soaked coil assembly to a mold of a flattening device, and flattening the coil assembly using a hydraulic press to make the thickness of the coil assembly reach a predetermined size, with a pressing pressure of 1.0 MPa to 1.5 MPa and a pressing time of 1 minute to 3 minutes; The flattening process reduces the gap between the coils, makes the coil group more compact, and enhances the mechanical strength and electrical performance of the coil group. In addition, the flattened coil group is more convenient for subsequent rolling and shaping processes.

[0045] S35, after the flattening process is completed, the flattened coil assembly is taken out from the mold and dried naturally or at low temperature to fully volatilize the ethanol inside the flattened coil assembly. Then the size and shape of the coil assembly are tested to confirm that it meets the design requirements, and the next step of the rolling process is prepared.

[0046] After the flattening process is completed, the flattened coil group is taken out of the mold and dried naturally or at low temperature. The drying process allows the ethanol inside the flattened coil group to fully evaporate, ensuring that no solvent remains inside the coil group to avoid affecting the insulation performance of the coil and the quality of subsequent processing. The dried flattened coil group has a stable size and shape In this embodiment, it is specifically described that step S4 specifically includes: S41, placing the flattened coil group on a feeding platform of a rolling machine, and adjusting initial parameters of the rolling machine, including rolling speed, rolling radius, and pressure settings; Place the flattened coil group obtained previously on the feeding platform of the coiling machine. According to the specific size and material properties of the coil group, adjust the initial parameters of the coiling machine, including the coiling speed, coiling radius and pressure setting. The coiling speed needs to match the plasticity of the coil material to ensure a smooth coiling process; the coiling radius is determined according to the designed inner and outer diameters of the coil cup to ensure that the finished product size meets the requirements; the pressure setting needs to be precisely controlled, so that sufficient pressure is applied to form the coil, but not excessively to avoid damaging the coil structure.

[0047] S42, starting the rolling machine, and gradually rolling the flattened coil group into a cylindrical coil cup through a preset guide device and a forming roller, and maintaining a uniform speed and a constant pressure during the rolling process to form a preliminary coil cup; The coiling machine is started and the flattened coil group is gradually rolled into a cylindrical coil cup using the preset guides and forming rollers. The guides ensure that the coil group maintains the correct path during the coiling process, and the forming rollers accurately form the coil group according to the set radius. During the coiling process, uniform speed and constant pressure are always maintained, which helps prevent uneven deformation of the coil or internal stress accumulation, ensuring that the shape and size of the preliminary coil cup are close to the design requirements.

[0048] S43, during the coiling process, a real-time monitoring system is activated to measure the key dimensions of the outer diameter and roundness of the coil cup online to obtain deviation data, and the real-time monitoring system includes a laser distance sensor and a displacement sensor; During the coiling process, the real-time monitoring system is activated to measure the key dimensions of the coil cup online. The real-time monitoring system includes a laser range sensor and a displacement sensor, which can accurately measure the key dimensions of the coil cup, such as the outer diameter and roundness, and obtain deviation data in real time. Through high-precision online detection, the dimensional deviation generated during the coiling process can be discovered in time, providing data support for subsequent adjustments.

[0049] In this embodiment, it is further explained that step S43 further includes: S44, comparing the deviation data with the preset standard size, if it is found that the size deviation of the coil cup exceeds the tolerance range, sending an adjustment instruction to the control system of the coiling machine; The deviation data obtained by the real-time monitoring system is compared with the preset standard size. If the size deviation of the coil cup is found to exceed the tolerance range (for example, ±0.02 mm), the system will immediately send an adjustment instruction to the control system of the coiling machine. Such a feedback mechanism ensures that any deviation can be detected in the shortest time possible, and measures can be taken quickly to prevent the deviation from further expanding and affecting product quality.

[0050] S45, the rolling machine automatically adjusts the working parameters of the rolling machine according to the received adjustment instruction, including fine-tuning the reel spacing, adjusting the pressure and correcting the rolling speed; The control system of the coiling machine automatically adjusts the working parameters of the coiling machine according to the adjustment instructions received. Specifically, the system will fine-tune the reel spacing to correct the inner and outer diameters of the coil; adjust the pressure to affect the degree of deformation of the coil material; and correct the coiling speed to adapt to the new processing conditions. Through the precise adjustment of these parameters, the dimensional deviations generated during the coiling process can be corrected in time to ensure that the size and shape of the coil cup gradually approach the standard value.

[0051] S46, after the coiling is completed, the coil cup is taken out from the coiling machine and placed in a shaping tooling, and the coil cup is subjected to a secondary shaping process by mechanical pressure or a shaping mold.

[0052] After the coiling is completed, the coil cup is removed from the coiling machine and placed in a shaping tool. The coil cup is subjected to a secondary shaping process by applying appropriate mechanical pressure or using a shaping die. This step is intended to further improve the dimensional accuracy and shape stability of the coil cup and eliminate deformation or stress concentration that may be left over during the coiling process. After shaping, the dimensional parameters of the coil cup should meet the design requirements.

[0053] In this embodiment, it is further explained that after step S5, the following steps are further included: S6, the size, resistance and inductance of the insulated motor coils are tested, and the inter-turn insulation performance of the coils is tested using inter-turn insulation testing equipment to sort qualified and unqualified products.

[0054] Conduct a comprehensive inspection of the insulated motor coils. First, measure the dimensional parameters of the coils, including the inner diameter, outer diameter, height, etc., to ensure that their dimensions meet the design specifications. Secondly, measure the resistance and inductance of the coils to verify whether their electrical performance meets the standards. Then, use the inter-turn insulation test equipment to test the inter-turn insulation performance of the coils to ensure that there are no short circuits or poor insulation between the turns of the coils. Finally, sort the coils into qualified and unqualified products based on the test results. Unqualified products require cause analysis and need to be reworked or scrapped.

[0055] Embodiment 2: The present invention further provides a production device for a motor coil, which is manufactured using the production method for a motor coil as in the first embodiment, and the production device comprises: The design module is used to obtain the specifications and performance requirements of the motor, calculate and determine the size data of a single coil.

[0056] The automatic winding machine is configured to wind a single coil of the wire material according to the size data. The automatic winding machine has the functions of winding speed control, tension adjustment, turn number setting and positioning.

[0057] The automated testing system is used to measure the width, resistance and inductance of the wound single coils and screen out qualified single coils.

[0058] The automatic lamination tool is configured to sequentially arrange six qualified single coils in a straight line in a partially covered manner, and the tool has a positioning device.

[0059] The vacuum impregnation and flattening device includes a vacuum container and a hydraulic press, which is used to immerse the wrapped single coil group into a 30% anhydrous ethanol solution under a vacuum environment, and then use a hydraulic press to flatten the coil group to obtain a flattened coil group.

[0060] The rolling machine is configured to roll the flattened coil group to form a cylindrical coil cup. The rolling machine includes a guide device and a forming roller.

[0061] The real-time monitoring system, including laser range finder and displacement sensor, is used to detect the key dimensions of the outer diameter and roundness of the coil cup during the coiling and shaping process, and collect real-time deviation data.

[0062] As described above, the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features thereof may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for producing a motor coil, characterized in that: include: According to the specifications and performance requirements of the motor, the dimension data of a single coil is designed, wherein the dimension data includes an inner diameter, an outer diameter and a height; Providing conductor materials, winding single coils according to the dimension data, and using an automated detection system to measure the width, resistance and inductance of the wound single coils to screen qualified single coils; Place six qualified single coils in a group into an automated lamination tool, wrap them tightly with high-temperature adhesive tape, and immerse them in 30% anhydrous ethanol in a vacuum environment for flattening to obtain a flattened coil group; Using a rolling machine to roll the flattened coil group to form a cylindrical coil cup, and during the rolling process, detecting the deviation of the coil cup through a real-time monitoring system, and shaping the coil cup according to the deviation data; The surface of the shaped coil cup is sealed and cured using a high-temperature insulating material to obtain an insulated motor coil.

2. The method for producing a motor coil according to claim 1, characterized in that: According to the specifications and performance requirements of the motor, the size data of the single coil is designed, including: Obtain the specifications and performance requirements of the designed motor, including rated power, rated speed, output torque, efficiency index, and allowable temperature rise range; Based on the specifications and performance requirements, calculate the electromagnetic design parameters of the motor and determine the required resistance value, inductance value, magnetic flux density and number of coil turns for a single coil; According to the calculated electromagnetic design parameters, the size data of the single coil is designed.

3. The method for producing a motor coil according to claim 2, characterized in that: The method further comprises designing the size data of the single coil according to the electromagnetic design parameters obtained by calculation, and then: The designed single coil is modeled by electromagnetic simulation software, its electromagnetic characteristics under working conditions are simulated, and the working parameters of the coil's resistance loss, magnetic leakage, and temperature rise are analyzed to verify the rationality of the designed dimensional data; According to the electromagnetic simulation results, the size data of the single coil is optimized and adjusted.

4. The method for producing a motor coil according to claim 1, characterized in that: The providing of the conductor material, winding of the single coil according to the dimension data, and measuring the width, resistance and inductance of the wound single coil by using an automated detection system to screen the qualified single coil specifically include: Select enameled copper wire that meets the standards as the conductor material, the wire diameter is the pre-set specification, and the insulation layer temperature resistance level is not less than 180℃; Pre-processing the conductor material, including appearance inspection and cleaning the conductor surface; According to the determined size data of the single coil, the winding parameters of the automatic winding machine are set, wherein the winding parameters include winding speed, tension control, number of turns and winding direction; Under constant temperature conditions, the automatic winding machine is used to wind a single coil. After the winding is completed, the single coil is removed from the winding machine and a shaping mold is used to shape the single coil.

5. The method for producing a motor coil according to claim 4, characterized in that: The single coil is removed from the winding machine, and a shaping die is used to shape the single coil, and then the single coil is sized: Use the visual component of the automated inspection system to measure the width of each single coil, record the measurement data, and compare it with the designed dimension data to determine whether the dimension is within the tolerance range; The resistance and inductance of each single coil are measured by the automatic detection system, and the test current is the standard current to obtain the electrical performance data. The measured width data and electrical performance data are imported into the quality control system, and a comprehensive evaluation is performed according to the preset qualification standards to screen out qualified single coils.

6. The method for producing a motor coil according to claim 1, characterized in that: The qualified single coils are placed in groups of six in an automated lamination tool, tightly wrapped with high-temperature adhesive tape, and immersed in 30% anhydrous ethanol in a vacuum environment for flattening to obtain a flattened coil group, specifically including: The qualified single coils are taken out one by one and placed in the positioning slot of the automatic lamination tooling according to a preset arrangement, wherein each subsequent single coil partially covers a part of the area of ​​the previous single coil and is arranged in a straight line in sequence, and the covering length is 20% to 45% of the length of the adjacent single coils; Adjust the positioning device in the automatic lamination tooling to position and angle each single coil, so that six single coils are stacked in the length direction to form a coil group, and the whole is arranged straight, and high-temperature adhesive tape of a preset width is used to tightly wrap the coil group along the length direction; Place the wrapped coil assembly as a whole into the container of the vacuum impregnation device, and slowly inject a 30% by mass ethanol solution in a vacuum environment with a vacuum degree of -0.08 MPa to -0.1 MPa for 3 to 5 minutes; The soaked coil assembly is transferred to a mold of a flattening device, and a hydraulic press is used to flatten the coil assembly so that the thickness of the coil assembly reaches a predetermined size. The pressing pressure is 1.0 MPa to 1.5 MPa, and the pressing time is 1 minute to 3 minutes. After the flattening process is completed, the flattened coil group is taken out from the mold and dried naturally or at a low temperature to fully volatilize the ethanol inside the flattened coil group.

7. The method for producing a motor coil according to claim 1, characterized in that: The method of using a rolling machine to roll the flattened coil group to form a cylindrical coil cup, detecting the deviation of the coil cup by a real-time monitoring system during the rolling process, and shaping the coil cup according to the deviation data specifically includes: Place the flattened coil group on the feeding platform of the coiling machine and adjust the initial parameters of the coiling machine, including coiling speed, coiling radius and pressure settings; The rolling machine is started to gradually roll the flattened coil group into a cylindrical coil cup through a preset guide device and a forming roller, and a uniform speed and a constant pressure are maintained during the rolling process to form a preliminary coil cup; During the coiling process, a real-time monitoring system is activated to measure the key dimensions of the outer diameter and roundness of the coil cup online to obtain deviation data. The real-time monitoring system includes a laser ranging sensor and a displacement sensor.

8. The method for producing a motor coil according to claim 1, characterized in that: During the coiling process, a real-time monitoring system is activated to measure the outer diameter and roundness of the coil cup online to obtain deviation data, and then the following is added: Comparing the deviation data with a preset standard size, and if it is found that the size deviation of the coil cup exceeds the tolerance range, sending an adjustment instruction to the control system of the coiling machine; The rolling machine automatically adjusts the working parameters of the rolling machine according to the received adjustment instructions, including fine-tuning the reel spacing, adjusting the pressure and correcting the rolling speed; After the coiling is completed, the coil cup is taken out of the coiling machine and placed in a shaping tooling, and the coil cup is subjected to a secondary shaping process by mechanical pressure or a shaping mold.

9. The method for producing a motor coil according to claim 1, characterized in that: The surface of the shaped coil cup is sealed and cured with a high temperature insulating material to obtain an insulated motor coil, and then the following steps are further included: The size, resistance and inductance of the insulated motor coils are tested, and the inter-turn insulation performance of the coils is tested using inter-turn insulation testing equipment to sort qualified and unqualified products.

10. A production device for motor coils, characterized in that: The motor coil is manufactured by the production method of any one of claims 1 to 9, wherein the production device comprises: Design module, used to obtain the specifications and performance requirements of the motor, calculate and determine the size data of a single coil; An automatic winding machine, configured to wind a single coil of the conductor material according to the dimension data, the automatic winding machine having winding speed control, tension adjustment, turn number setting and positioning functions; The automated testing system is used to measure the width, resistance and inductance of the wound single coils and select qualified single coils; An automatic lamination tooling, configured to sequentially arrange six qualified single coils in a straight line in a partially covered manner, the tooling having a positioning device; A vacuum impregnation and flattening device, comprising a vacuum container and a hydraulic press, is used to immerse the wrapped single coil assembly into a 30% anhydrous ethanol solution under a vacuum environment, and then use the hydraulic press to flatten the coil assembly to obtain a flattened coil assembly; A rolling machine configured to roll the flattened coil group to form a cylindrical coil cup, the rolling machine comprising a guide device and a forming roller; The real-time monitoring system, including laser range finder and displacement sensor, is used to detect the key dimensions of the outer diameter and roundness of the coil cup during the coiling and shaping process, and collect real-time deviation data.

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