Stator wave winding forming process and equipment

Abstract

The invention discloses a stator wave winding forming technology and equipment, the technology comprises the steps of 2D forming, 3D pre-forming and 3D punch forming in sequence, and the equipment used in the technology comprises a 2D forming device, 3D pre-forming equipment and 3D punch forming equipment; after the 2D wave winding is processed to be annular or ring-shaped, the overall structure of the winding is more stable, subsequent stamping operation is facilitated, scattering or dislocation of the winding is avoided, the 2D wave winding is processed to be ring-shaped, wires can be more uniformly distributed, the arrangement density of the wires can be adjusted, the utilization rate of stator slots can be optimized, the power density and efficiency of the motor are improved, and the service life of the motor is prolonged. After the 2D wave winding wire is made into a ring shape, the coil forms a closed integral structure, the position of the winding can be more accurately kept during stamping, and the risks of deformation and dislocation are reduced.

Description

Technical Field

[0001] The invention belongs to the field of wave winding forming equipment, and in particular, relates to a stator wave winding forming process and equipment. Background Art

[0002] In many manufacturing processes, wave-wound wire 3D forming technology is usually direct three-dimensional forming, that is, in the slots of the stator or in the winding space, the wire is directly arranged into a three-dimensional spatial structure according to the wave trajectory.

[0003] However, in the case of a specific stator design (such as an out-slot winding or a stator with a special shape), directly 3D stamping the stator winding wave line cannot meet the requirements of the specific stator shape.

[0004] Therefore, the method of first 2D forming the wave winding into a complex shape and then 3D stamping was adopted to meet the production requirements of specific stators, but a new problem was faced:

[0005] After 2D wave winding is processed, the wire is relatively loose and easy to deform. Direct use for 3D molding will cause the winding shape to be out of control and affect the motor performance.

[0006] Therefore, a process and equipment are needed that can ensure that the stator winding wire formed in 2D will not be deformed after 3D stamping while satisfying the requirement of forming the stator winding wire in a specific shape through 2D molding. Summary of the invention

[0007] In view of the above defects, the present invention provides a stator wave winding forming process, comprising the following steps:

[0008] S1: placing a single straight-wound wave line in a 2D forming device, and realizing one-step forming of the 2D-wound wave line by extruding both sides of the straight-wound wave line simultaneously;

[0009] S2: placing the 2D wave-wound wire on a 3D preforming device for pre-winding to form a 2D-formed wave-wound wire sleeve;

[0010] S3: Put the wave winding sleeve on the 3D stamping and forming equipment, and stamp the upper and lower ends of the adjusted single pre-wound 2D wave winding wire to form the final wave winding wire;

[0011] S4: Repeat steps S1-S3 to form the required wave winding wire, and then place them one by one on the winding machine to form the stator coil.

[0012] Further, the pre-winding process comprises the following steps:

[0013] S2-1, conveying the 2D wave line formed by the 2D forming device into a plane to the 3D preforming equipment for preforming preparation;

[0014] S2-2, each bent end of the planar 2D winding wave line is sequentially wound onto the surface of the 3D preforming device;

[0015] S2-3. The planar 2D wave-wound wire is completely wound onto the surface of the 3D preformed device to form a wave-wound wire sleeve.

[0016] The present invention also discloses a stator wave winding forming device applied to the above-mentioned stator wave winding forming process, comprising a 2D forming device, a 3D preforming device and a 3D stamping forming device which are sequentially installed on the same workbench;

[0017] The 2D forming device comprises a moving mechanism installed on the top of the workbench, a forming mechanism and a moving end forming folding line mechanism installed on the top of the moving mechanism and driven by the moving mechanism, and a fixed end forming folding line mechanism installed on the top of the workbench for cooperating with the forming mechanism to fix the winding line;

[0018] The 3D preforming equipment includes an adjustment lifting mechanism and a pre-winding mechanism installed on the top of the workbench;

[0019] The 3D stamping forming equipment comprises a supporting component installed on the top of a workbench and a stamping component surrounding the outside of the supporting component.

[0020] Furthermore, the forming mechanism is used to punch the end corner of the straight wave line, and the mobile end forming folding line mechanism is used to fold the straight wave line at the end corner of the punching into a bent wave line.

[0021] Furthermore, the adjusting lifting mechanism is used to transport the 2D-molded wave-wound wire to the bottom of the pre-winding mechanism, and the pre-winding mechanism is used to perform pre-winding processing on the 2D-molded wave-wound wire.

[0022] Furthermore, the support component is used to sleeve the pre-wound wave winding sleeve, and the stamping component is used to stamp and form the wave winding sleeve at the stamping die fixed on the outer ring of the support component.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] 1. Structure with stable winding: Pre-winding process improves the stability of winding and reduces the risk of direct stamping.

[0025] 2. Optimize winding performance: The combination of coil preforming and stamping improves the filling density, mechanical strength and heat dissipation performance of the winding.

[0026] 3. Ability to meet complex needs: The step-by-step process is more flexible and suitable for complex stator designs and three-dimensional geometries.

[0027] 4. Improve production feasibility: The multi-step process reduces errors and improves the consistency and efficiency of motor production.

[0028] 5. After the 2D wave winding is processed into a ring or loop shape, the overall structure of the winding will be more stable, which is convenient for subsequent stamping operations and avoids the scattering or misalignment of the winding. By processing the 2D wave winding into a loop, the wire can be distributed more evenly and its arrangement density can be adjusted, which helps to optimize the utilization of the stator slots and thus improve the power density and efficiency of the motor. After the 2D wave winding is made into a loop, the coil forms a closed overall structure, which can more accurately maintain the position of the winding during stamping, reducing the risk of deformation and misalignment. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 Schematic diagram of 2D winding wave line in the present invention.

[0030] Figure 2 It is a schematic diagram of the pre-winding process of the wave line in the present invention.

[0031] Figure 3 Schematic diagram of the final wave winding in the present invention.

[0032] Figure 4 This is a three-dimensional schematic diagram of the 2D molding device in operation.

[0033] Figure 5 This is a three-dimensional schematic diagram of the 3D preforming equipment in operation.

[0034] Figure 6 This is a three-dimensional schematic diagram of the 3D stamping equipment in operation.

[0035] Figure 7 It is a three-dimensional schematic diagram of the 2D molding device after operation.

[0036] Figure 8 This is a three-dimensional schematic diagram of the 3D preforming equipment in operation.

[0037] Fig. 9 This is a three-dimensional schematic diagram of the 3D stamping equipment in operation.

[0038] In the figure: 11, 2D forming device; 22, 3D preforming equipment; 33, 3D stamping forming equipment; 2, moving mechanism; 3, forming mechanism; 4, moving end forming folding line mechanism; 5, fixed end forming folding line mechanism; 6, adjustment jacking mechanism; 7, pre-winding mechanism; 8, support assembly; 9, stamping assembly. DETAILED DESCRIPTION

[0039] In order to facilitate the understanding of the present invention, the device of the present invention will be described more fully below with reference to the relevant drawings. Embodiments of the device are given in the drawings. However, the device can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present invention more thorough and comprehensive.

[0040] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "set" should be understood in a broad sense, for example, they can be fixedly connected or set, or detachably connected or set, or integrally connected or set. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0041] Example

[0042] like Figure 1-3 As shown, this embodiment provides a stator wave winding forming process, including the following steps:

[0043] S1: placing a single straight winding wave line in a 2D forming device 11, and realizing one-step forming of the 2D winding wave line by simultaneously squeezing both sides of the straight winding wave line, such as Figure 1 As shown;

[0044] S2: placing the 2D winding line at the 3D preforming device 22 for pre-winding processing:

[0045] S2-1, conveying the 2D wave line formed by the 2D forming device into a plane to the 3D preforming device 22 for preforming preparation;

[0046] S2-2, each bent end of the planar 2D winding line is sequentially wound onto the surface of the 3D preforming device 22;

[0047] S2-3, the planar 2D wave winding wire is completely wound onto the surface of the 3D preforming device 22 to form a wave winding wire sleeve, such as Figure 2 As shown;

[0048] S3: Put the wave winding sleeve on the 3D stamping and forming device 33, and stamp the upper and lower ends of the adjusted single pre-wound 2D wave winding wire to form the final wave winding wire, such as Figure 3 As shown;

[0049] S4: Repeat steps S1-S3 to form the required wave winding wire, and then place them one by one on the winding machine to form the stator coil.

[0050] The equipment used in the above process is specifically a 2D molding device 11, a 3D pre-molding device 22 and a 3D stamping molding device 33 which are sequentially installed on the same workbench;

[0051] like Figure 4 and Figure 7 As shown, the 2D forming device 11 includes a moving mechanism 2 installed on the top of the workbench, a forming mechanism 3 installed on the top of the moving mechanism 2 and driven by it, a moving end forming folding line mechanism 4, and a fixed end forming folding line mechanism 5 installed on the top of the workbench for cooperating with the forming mechanism 3 to fix the winding line. In detail, the forming mechanism 3 is used to punch the end angle of the straight winding line, and the moving end forming folding line mechanism 4 is used to drive the straight winding line of the end angle at the punching place through the driving of the moving mechanism 2 to gradually approach the fixed end forming folding line mechanism 5, thereby pushing the straight winding line to be folded into a bent winding line;

[0052] like Figure 5 and Figure 8 As shown, the 3D preforming device 22 includes an adjustment lifting mechanism 6 and a pre-winding mechanism 7 installed on the top of the workbench. In detail, the adjustment lifting mechanism 6 is used to transport the 2D formed bending and winding wave line to the bottom of the pre-winding mechanism 7. As the pre-winding mechanism 7 rotates, the bottom winding wave line is hooked and wound to form a wave winding line sleeve, thereby realizing the pre-winding process of the 2D formed bending and winding wave line;

[0053] like Figure 6 and Fig. 9 As shown, the 3D stamping and forming equipment 33 includes a support component 8 installed on the top of the workbench and a stamping component 9 surrounding the outside of the support component 8. In detail, the pre-winding wave winding sleeve is arranged on the outside of the support component 8, and the stamping component 9 is used to stamp and form the wave winding sleeve at the stamping die fixed on the outer circle of the support component 8, that is, to obtain the final wave winding. It should be noted that the stamping component 9 and the stamping die can correspond one by one (such as stamping components 9 and stamping dies set in different shapes, angles, and positions).

[0054] It should be noted that the structure described in the present invention can be implemented in a variety of different forms and is not limited to the described embodiments. Any equivalent transformations made by ordinary technicians in this field using the contents of the present invention description and drawings, or directly or indirectly applied to other related technical fields, such as the loading and unloading of other items, are included in the protection scope of the present invention.

Claims

1. Stator wave winding forming process, characterized by: The following steps are involved: S1: placing a single straight-wound wave line in a 2D forming device, and realizing one-step forming of the 2D-wound wave line by extruding both sides of the straight-wound wave line simultaneously; S2: placing the 2D wave-wound wire on a 3D preforming device for pre-winding to form a 2D-formed wave-wound wire sleeve; S3: Put the wave winding sleeve on the 3D stamping and forming equipment, and stamp the upper and lower ends of the adjusted single pre-wound 2D wave winding wire to form the final wave winding wire; S4: Repeat steps S1-S3 to form the required wave winding wire, and then place them one by one on the winding machine to form the stator coil.

2. The stator wave winding forming process according to claim 1, characterized in that: The pre-winding process comprises the following steps: S2-1, conveying the 2D wave line formed by the 2D forming device into a plane to the 3D preforming equipment for preforming preparation; S22, each bent end of the planar 2D winding line is sequentially wound onto the surface of the 3D preforming device; S2-3. The planar 2D wave-wound wire is completely wound onto the surface of the 3D preformed device to form a wave-wound wire sleeve.

3. Stator wave winding forming equipment, applied to the stator wave winding forming process according to claims 1-2, characterized in that: It includes a 2D forming device, a 3D preforming device and a 3D stamping forming device which are sequentially installed on the same workbench; The 2D forming device comprises a moving mechanism installed on the top of the workbench, a forming mechanism and a moving end forming folding line mechanism installed on the top of the moving mechanism and driven by the moving mechanism, and a fixed end forming folding line mechanism installed on the top of the workbench for cooperating with the forming mechanism to fix the winding line; The 3D preforming equipment includes an adjustment lifting mechanism and a pre-winding mechanism installed on the top of the workbench; The 3D stamping forming equipment comprises a supporting component installed on the top of a workbench and a stamping component surrounding the outside of the supporting component.

4. The stator wave winding forming device according to claim 3, characterized in that: The forming mechanism is used to punch the end corner of the straight wave line, and the moving end forming folding line mechanism is used to fold the straight wave line at the end corner of the punching into a bent wave line.

5. The stator wave winding forming equipment according to claim 3, characterized in that: The adjusting lifting mechanism is used to transport the 2D-molded wave winding wire to the bottom of the pre-winding mechanism, and the pre-winding mechanism is used to pre-wind the 2D-molded wave winding wire.

6. The stator wave winding forming equipment according to claim 3, characterized in that: The support component is used for sleeve-mounting the pre-wound wave winding sleeve, and the stamping component is used for stamping and forming the wave winding sleeve at the stamping die fixed on the outer ring of the support component.

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