Stator wave winding forming process and equipment

Abstract

This invention discloses a stator wave winding forming process and equipment, including sequential 2D forming, 3D preforming, and 3D stamping forming steps. The equipment used in the process includes a 2D forming device, a 3D preforming device, and a 3D stamping forming device. After processing the 2D wave winding into a ring or coil shape, the overall structure of the winding will be more stable, which facilitates subsequent stamping operations and avoids the scattering or misalignment of the winding. By processing the 2D wave winding into a coil shape, the wire can be distributed more evenly and its arrangement density can be adjusted, which helps to optimize the utilization rate of the stator slots, thereby improving the power density and efficiency of the motor. After the 2D wave winding is made into a coil shape, the coil forms a closed overall structure, which can more accurately maintain the position of the winding during stamping and reduce the risk of deformation and misalignment.

Description

Technical Field

[0001] This invention belongs to the field of wave winding equipment, and more specifically, relates to stator wave winding forming process and equipment. Background Technology

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

[0003] However, for specific stator designs (such as external slot windings or stators with special shapes), directly 3D stamping the stator windings cannot meet the requirements of the specific stator shape.

[0004] Therefore, a method was adopted to first 2D mold the complex-shaped corrugated wire and then perform 3D stamping to meet the manufacturing requirements of specific stators. However, this led to a new problem:

[0005] After the 2D wave winding is processed, the wire is relatively loose and easily deformed. If it is used directly for 3D molding, the winding shape will be out of control and affect the motor performance.

[0006] Therefore, there is a need for a process and equipment that can ensure the stator winding wire formed in 2D will not deform after 3D stamping, provided that it is formed into a specific shape in 2D. Summary of the Invention

[0007] To address the above deficiencies, this invention provides a stator wave winding forming process, comprising the following steps:

[0008] S1: Place a single straight-wound wavy line in a 2D forming device, and simultaneously squeeze both sides of the straight-wound wavy line to achieve one-step forming of the 2D wavy line.

[0009] S2: Place the 2D winding wire at the 3D preforming equipment for pre-winding to form a 2D shaped winding wire sleeve.

[0010] S3: Place the corrugated wire sleeve on the 3D stamping forming equipment and stamp the upper and lower ends of the adjusted single pre-wound 2D corrugated wire to form the final corrugated wire.

[0011] S4: Repeat steps S1-S3 to form the required wave windings, and then place them one by one at the winding machine to make stator coils.

[0012] Furthermore, the pre-winding process includes the following steps:

[0013] S2-1. The 2D wave-shaped wire, which is flat after being formed by the 2D molding device, is conveyed to the 3D preforming equipment for preforming preparation.

[0014] S2-2, The bending ends of the 2D wavy line on the plane are sequentially wound onto the surface of the 3D preforming equipment;

[0015] S2-3. The 2D wave-shaped wire is completely wound onto the surface of the 3D preforming equipment to form a wave-shaped wire sleeve.

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

[0017] The 2D molding device includes a moving mechanism mounted on the top of the worktable, a molding mechanism mounted on the top of the moving mechanism and driven by it, a moving end molding folding mechanism, and a fixed end molding folding mechanism mounted on the top of the worktable for cooperating with the molding mechanism to fix the winding folding line.

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

[0019] The 3D stamping equipment includes a support assembly mounted on the top of the worktable and a stamping assembly surrounding the support assembly.

[0020] Furthermore, the forming mechanism is used to press the straight-line wavy line at the end corner, and the moving end forming folding mechanism is used to fold the straight-line wavy line at the end corner of the press into a bent wavy line.

[0021] Furthermore, the adjusting lifting mechanism is used to transport the 2D-formed winding wire to the bottom of the pre-winding mechanism, which is used to pre-wind the 2D-formed winding wire.

[0022] Furthermore, the support assembly is used to fit the pre-wound corrugated wire sleeve, and the stamping assembly is used to stamp the corrugated wire sleeve located at the stamping die fixed on the outer ring of the support assembly.

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

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

[0025] 2. Optimized winding performance: The combination of coil preforming and stamping improves the winding's filler density, mechanical strength, and heat dissipation performance.

[0026] 3. Capable of meeting complex requirements: The step-by-step process is more flexible and suitable for complex stator designs and three-dimensional geometries.

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

[0028] 5. After processing the 2D wave winding into a ring or coil, the overall structure of the winding will be more stable, which will facilitate subsequent stamping operations and avoid the winding from becoming scattered or misaligned. By processing the 2D wave winding into a coil, the wire can be distributed more evenly and its arrangement density can be adjusted, which helps to optimize the utilization rate of the stator slots, thereby improving the power density and efficiency of the motor. After the 2D wave winding is made into a coil, the coil forms a closed overall structure, which can more accurately maintain the position of the winding during stamping and reduce the risk of deformation and misalignment. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the 2D wavy line in this invention.

[0030] Figure 2 This is a schematic diagram of the pre-wound wave line in this invention.

[0031] Figure 3 This is a schematic diagram of the final wave winding in this 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 a 3D stamping forming equipment in operation.

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

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

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

[0038] In the diagram: 11. 2D forming device; 22. 3D preforming equipment; 33. 3D stamping forming equipment; 2. Moving mechanism; 3. Forming mechanism; 4. Moving end forming folding mechanism; 5. Fixed end forming folding mechanism; 6. Adjustment and lifting mechanism; 7. Pre-winding mechanism; 8. Support assembly; 9. Stamping assembly. Detailed Implementation

[0039] To facilitate understanding of the present invention, the apparatus of the present invention will now be described more fully with reference to the accompanying drawings. Embodiments of the apparatus are shown in the drawings. However, the apparatus can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to make the disclosure of the present invention more thorough and complete.

[0040] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "configuration" should be interpreted broadly. For example, they can refer to a fixed connection or configuration, a detachable connection or configuration, or an integral connection or configuration. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the 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: A single straight-wound corrugated wire is placed inside the 2D forming device 11. By simultaneously pressing both sides of the straight-wound corrugated wire, one-step forming of the 2D corrugated wire is achieved. Figure 1 As shown;

[0044] S2: Place the 2D winding wire at point 22 of the 3D preforming equipment for pre-winding:

[0045] S2-1. The 2D wave-shaped wire, which is flat after being formed by the 2D molding device, is conveyed to the 3D preforming equipment 22 for preforming preparation.

[0046] S2-2, The bending ends of the 2D wavy line on the plane are sequentially wound onto the surface of the 3D preforming equipment 22;

[0047] S2-3, The 2D wave-shaped wire on the plane is completely wound onto the surface of the 3D preforming equipment 22 to form a wave-shaped wire sleeve, such as... Figure 2 As shown;

[0048] S3: Place the corrugated wire sleeve onto the 3D stamping forming equipment 33, and stamp the upper and lower ends of the adjusted single pre-wound 2D corrugated wire to form the final corrugated wire, such as... Figure 3 As shown;

[0049] S4: Repeat steps S1-S3 to form the required wave windings, and then place them one by one at the winding machine to make stator coils.

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

[0051] like Figure 4 and Figure 7 As shown, the 2D forming device 11 includes a moving mechanism 2 mounted on the top of the worktable, a forming mechanism 3 mounted on the top of the moving mechanism 2 and driven by it, and a moving end forming folding mechanism 4, as well as a fixed end forming folding mechanism 5 mounted on the top of the worktable for cooperating with the forming mechanism 3 to fix the wavy line. In detail, the forming mechanism 3 is used to press the end corner of the straight wavy line, and the moving end forming folding mechanism 4 is used to drive the straight wavy line at the end corner of the press to move gradually closer to the fixed end forming folding mechanism 5 through the driving of the moving mechanism 2, thereby pushing the straight wavy line to fold into a bent wavy line.

[0052] like Figure 5 and Figure 8 As shown, the 3D preforming equipment 22 includes an adjustment lifting mechanism 6 and a pre-winding mechanism 7 installed on the top of the worktable. In detail, the adjustment lifting mechanism 6 is used to transport the 2D formed bent wavy line to the bottom of the pre-winding mechanism 7. As the pre-winding mechanism 7 rotates, it hooks and winds the bottom wavy line to form a wavy line sleeve, thereby realizing the pre-winding treatment of the 2D formed bent wavy line.

[0053] like Figure 6 and Figure 9 As shown, the 3D stamping forming equipment 33 includes a support component 8 installed on the top of the worktable and a stamping component 9 surrounding the support component 8. Specifically, the pre-wound corrugated wire sleeve is fitted onto the outside of the support component 8. The stamping component 9 is used to stamp the corrugated wire sleeve located at the stamping die fixed on the outer ring of the support component 8, thus obtaining the final corrugated wire. It should be noted that the stamping component 9 and the stamping die can correspond one-to-one (such as stamping components 9 and stamping dies with different shapes, angles, and positions).

[0054] It should be noted that the structure described in this invention can be implemented in many different forms and is not limited to the embodiments described. Any equivalent transformations made by those skilled in the art based on the description and drawings of this invention, or direct or indirect applications in other related technical fields, such as the loading and unloading of other items, are included within the protection scope of this invention.

Claims

1. A stator wave winding forming process, characterized in that: Includes the following steps: S1: Place a single straight-wound wavy line in a 2D forming device, and simultaneously squeeze both sides of the straight-wound wavy line to achieve one-step forming of the 2D wavy line. S2: Place the 2D winding wire at the 3D preforming equipment for pre-winding to form a 2D shaped winding wire sleeve. S3: Place the corrugated wire sleeve on the 3D stamping forming equipment and stamp the upper and lower ends of the adjusted single pre-wound 2D corrugated wire to form the final corrugated wire. S4: Repeat steps S1-S3 to form the required wave windings, and then place them one by one at the winding machine to make stator coils.

2. The stator wave winding forming process as described in claim 1, characterized in that: The pre-winding process includes the following steps: S2-1. The 2D wave-shaped wire, which is flat after being formed by the 2D molding device, is conveyed to the 3D preforming equipment for preforming preparation. S22. The various bends of the 2D wavy line on the plane are sequentially wound onto the surface of the 3D preforming equipment. S2-3. The 2D wave-shaped wire is completely wound onto the surface of the 3D preforming equipment to form a wave-shaped wire sleeve.

3. A stator wave winding forming equipment, applied to the stator wave winding forming process described in claims 1-2, characterized in that: It includes a 2D forming device, a 3D preforming device, and a 3D stamping forming device, which are installed sequentially on the same workbench; The 2D molding device includes a moving mechanism mounted on the top of the worktable, a molding mechanism mounted on the top of the moving mechanism and driven by it, a moving end molding folding mechanism, and a fixed end molding folding mechanism mounted on the top of the worktable for cooperating with the molding mechanism to fix the winding folding. The 3D preforming equipment includes an adjustment lifting mechanism and a pre-winding mechanism installed on the top of the worktable; The 3D stamping equipment includes a support assembly mounted on the top of the worktable and a stamping assembly surrounding the support assembly.

4. The stator wave winding forming equipment as described in claim 3, characterized in that: The forming mechanism is used to press the straight wavy line at the end corner, and the moving end forming folding mechanism is used to fold the straight wavy line at the end corner of the press into a bent wavy line.

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

6. The stator wave winding forming equipment as described in claim 3, characterized in that: The support component is used to fit the pre-wound corrugated wire sleeve, and the stamping component is used to stamp the corrugated wire sleeve at the stamping die located on the outer ring of the support component.

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