A branching block, a welding clamping tool and a positioning method thereof

Abstract

The application discloses a wire distribution block, a clamping tool for welding and a positioning method thereof. The wire distribution block comprises a wire distribution block main body part and a first separation part. The wire distribution block main body part is arranged along the radial direction of the disc body of a flat wire motor. Limiting surfaces or limiting lines are arranged on the two side surfaces of the wire distribution block main body part, and the limiting surfaces or limiting lines are used for abutting against the side surfaces of two circumferentially adjacent copper bars. The first separation part is arranged on at least one side surface of the wire distribution block main body part and protrudes from the wire distribution block main body part along the circumferential direction. The first separation part comprises a plurality of first separation blocks which are arranged at intervals along the radial direction. When the wire distribution block moves downward, the first separation blocks can be inserted into the welding gap between the terminals of two radially adjacent copper bars.

Description

Technical Field

[0001] This invention relates to the field of laser welding of flat wire motor stators, specifically to a wire separator, a welding clamping fixture, and a positioning method thereof. Background Technology

[0002] Currently, with the widespread adoption of electric vehicles, flat wire stator winding structures have been mass-produced for electric drive stators in new energy vehicles. Due to increasingly higher requirements for power density and motor efficiency, electric drive manufacturers have begun developing ultra-low-end flat wire stators, where the straight section at the welding end has been reduced from 10mm to 5mm. Traditional welding fixtures can no longer meet these requirements. Furthermore, existing welding clamping fixtures only clamp the copper busbar units from the outside, making it impossible to guarantee the welding gap between the copper busbar terminals, thus affecting the final welding quality.

[0003] Therefore, it is urgent to propose a new solution to the above problems. Summary of the Invention

[0004] This invention provides a wire divider block, a welding clamping fixture, and a positioning method thereof to solve the problem that existing welding clamping fixtures cannot meet the requirements of ultra-low end flat wire stators, and only clamp the copper busbar assembly unit from the outside, which makes it impossible to guarantee the welding gap between the copper busbar terminals, thus affecting the final welding quality.

[0005] This invention proposes a line divider block, comprising a line divider block main body and a first partition portion;

[0006] The main body of the wire dividing block is arranged along the radial direction of the flat wire motor disc;

[0007] The main body of the dividing block is provided with limiting surfaces or limiting lines on both sides, and the limiting surfaces or limiting lines are used to abut against the sides of two adjacent sets of copper busbars in the circumferential direction.

[0008] The first dividing portion is disposed on at least one side of the main body of the dividing block and protrudes circumferentially from the main body of the dividing block; the first dividing portion includes a plurality of first dividing blocks arranged radially at intervals, the first dividing blocks being used to insert into the welding gap between two radially adjacent copper busbar terminals when the dividing block moves downward.

[0009] Furthermore, the left and right sides of the main body of the splitter block also include a second inclined surface. The second inclined surface extends upward from the lower end of the main body of the splitter block towards the side of the copper busbar on the same side and is inclined, and is connected to the limiting surface or limiting line.

[0010] Furthermore, the left and right sides of the main body of the splitter block also include a first inclined surface. The first inclined surface extends downward from the upper end of the main body of the splitter block towards the side of the copper busbar on the same side and is inclined, and is connected to the limiting surface or limiting line.

[0011] Furthermore, interference avoidance surfaces are provided on the upper left and right sides of the main body of the dividing block. The interference avoidance surfaces are located above the first partition and are used to prevent the main body of the dividing block from colliding with the welding protrusion when the main body of the dividing block moves upward after welding.

[0012] Furthermore, the first partition extends upward over the limiting surface or limiting line on the second inclined surface and protrudes from the limiting surface or limiting line.

[0013] Furthermore, the first dividing block includes an upper tilting unit and a lower tilting unit. The lower tilting unit extends and tilts from bottom to top in a direction close to the side of the copper busbar on the same side, and the upper tilting unit extends and tilts from top to bottom in a direction close to the side of the copper busbar on the same side. The upper tilting unit and the lower tilting unit intersect.

[0014] Furthermore, the downward tilting unit is provided with a V-shaped protrusion to facilitate the downward insertion of the main body of the dividing block.

[0015] The present invention also provides a welding clamping fixture, including the above-mentioned wire dividing block, and further including a gripper and a sliding mechanism;

[0016] The gripper includes a first gripper and a second gripper located on both sides of the wire divider block. The first gripper includes a rod portion arranged in the radial direction of the flat wire motor disc body, and a second support connection portion arranged at one end of the rod portion. The rod portion is provided with a plurality of clamping grooves at intervals on the side facing the wire divider block. During welding, the clamping grooves are used to clamp and limit two radially adjacent copper busbars being welded.

[0017] The sliding mechanism is used to drive the first and second grippers to move toward each other, thereby clamping multiple copper busbar units.

[0018] Furthermore, the clamping groove includes a groove bottom, and protrusions are provided on both sides of the groove bottom. The protrusions are used to limit and clamp the two copper busbars of a single copper busbar group unit during welding. The groove bottom is provided with a second partition block corresponding to the first partition block. During welding, the second partition block is inserted between two radially adjacent copper busbars being welded.

[0019] The present invention also provides a positioning method for a welding clamping fixture, comprising the following steps:

[0020] The dividing block moves downward, and the main body of the dividing block moves downward to separate two adjacent copper busbars in the circumferential direction. At the same time, multiple first dividing blocks are inserted into the welding gap between the terminals of two radially adjacent copper busbars.

[0021] By manipulating the sliding mechanism, the first and second grippers move towards the middle dividing block simultaneously. The clamping surfaces or lines abut against the sides of the two adjacent copper busbars, and the multiple copper busbar groups are clamped together by cooperating with the first dividing block, the clamping groove and the protrusion.

[0022] After welding, the sliding mechanism is manipulated to move the first and second grippers away from the wire divider block. In addition, the wire divider block retracts upward from the copper wire terminal welding protrusion through the interference avoidance surface provided on the side.

[0023] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0024] 1. The present invention separates two adjacent copper busbars in a circumferential direction by moving the main body of the dividing block downward. Then, by setting limiting surfaces or limiting lines on both sides of the main body of the dividing block to abut against the sides of the two adjacent copper busbars in a circumferential direction, when the dividing block moves downward, the first separating block can be inserted into the welding gap between the terminals of two radially adjacent copper busbars.

[0025] 2. The welding clamping fixture of the present invention abuts against the sides of two adjacent sets of copper busbars circumferentially through a limiting surface or limiting line, and then clamps multiple copper busbar groups by cooperating with the first partition block, clamping groove and protrusion. Then, the sliding mechanism drives the two jaws to move towards each other to clamp multiple sets of copper busbar groups. When the dividing block moves downward, the first partition block is inserted into the welding gap between two radially adjacent copper busbar terminals to ensure that the two copper busbar terminals are clamped and that there is a suitable welding gap, thereby ensuring that no axial movement occurs during welding, ensuring welding quality, and also effectively preventing welding spatter.

[0026] 3. The positioning method of the welding clamping fixture of the present invention firstly positions the copper busbar group unit from the middle by moving the dividing block downwards, and then clamps multiple copper busbar group units simultaneously by the first and second clamping jaws that cooperate with it. The limiting surface or limiting line abuts against the side of two adjacent groups of copper busbars circumferentially, and then clamps multiple copper busbar group units by cooperating with the first dividing block, the clamping groove and the protrusion. This results in higher welding accuracy. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of the dividing block of the present invention;

[0028] Figure 2 This is a top view of the dividing block of the present invention;

[0029] Figure 3 This is a side view of the dividing block of the present invention;

[0030] Figure 4 This is a top view of the gripper of the present invention;

[0031] Figure 5 This is a schematic diagram of the structure of the dividing block and the gripper of the present invention;

[0032] Figure 6 This is a top view of the dividing block and gripper of the present invention;

[0033] Figure 7 This is a top view of the wire divider block, clamps, and copper bus terminals of the present invention;

[0034] Figure 8 for Figure 7 Enlarged view of point A in the middle;

[0035] Figure 9 This is a schematic diagram of the welding clamping fixture of the present invention;

[0036] Figure 10 This is a schematic diagram of the welding clamping fixture and flat wire stator winding structure of the present invention;

[0037] Figure 11 for Figure 10 Enlarged view of point B in the middle;

[0038] Reference numerals: 1. Divider block; 11. Divider block main body; 111. First inclined surface; 112. Second inclined surface; 113. Interference avoidance surface; 114. Limiting line; 12. First partition; 121. Upper inclined unit; 122. Lower inclined unit; 1221. V-shaped protrusion; 13. First support connection; 2. Gripper; 21. Rod; 211. Grip groove; 2111. Groove bottom; 2112. Second partition block; 212. Protrusion; 22. Second support connection; 3. Sliding mechanism; 31. First base; 32. Second base; 33. Sliding positioning pin; 34. Assembly base plate; 4. Flat wire stator winding structure; 41. Copper busbar grouping unit. Detailed Implementation

[0039] To further understand the invention's content, features, and effects, the following embodiments are provided, along with accompanying drawings. Figures 1-11 The details are as follows.

[0040] like Figures 1-3 As shown, an embodiment of the present invention provides a dividing block 1, including a dividing block main body 11 and a first dividing part 12;

[0041] The main body 11 of the wire divider is arranged along the radial direction of the flat wire motor disc;

[0042] Limiting lines 114 are provided on both sides of the main body 11 of the branch block. The limiting lines 114 are used to abut against the sides of two adjacent sets of copper busbars in the circumferential direction. The limiting lines 114 can also be replaced by limiting surfaces with a certain height.

[0043] The first dividing part 12 is provided on the left and right sides of the main body of the dividing block 11, or it can be provided on only one side, protruding from the main body of the dividing block 11 in the circumferential direction; the first dividing part 12 includes a plurality of first dividing blocks arranged radially at intervals, the first dividing blocks being used to insert into the welding gap between two radially adjacent copper busbar terminals when the dividing block 1 moves downward.

[0044] The present invention separates two adjacent copper busbars in a circumferential direction by moving the main body of the splitter block downward. Then, by setting limiting surfaces or limiting lines on both sides of the main body of the splitter block to abut against the sides of the two adjacent sets of copper busbars in a circumferential direction, when the splitter block moves downward, the first separating block can be inserted into the welding gap between the terminals of two radially adjacent copper busbars.

[0045] In this embodiment, as Figures 1-3 As shown, the left and right sides of the main body 11 of the splitter block also include a second inclined surface 112. The second inclined surface 112 extends upward from the lower end of the main body 11 of the splitter block towards the side of the copper busbar on the same side and is inclined, and is connected to the limiting line 114, so as to facilitate the downward movement of the main body 11 of the splitter block, thereby separating the two adjacent copper busbars in the circumferential direction.

[0046] In this embodiment, as Figures 1-3 As shown, the left and right sides of the main body 11 of the splitter block also include a first inclined surface 111. The first inclined surface 111 extends downward from the upper end of the main body 11 of the splitter block towards the side of the copper busbar on the same side and is inclined, and is connected to the limiting line 114. The limiting line 114 serves as the dividing line between the first inclined surface 111 and the second inclined surface 112, which facilitates the upward movement of the main body 11 of the splitter block.

[0047] In this embodiment, as Figures 1-3 As shown, interference avoidance surfaces 113 are provided on the upper left and right sides of the main body 11 of the dividing block. The interference avoidance surfaces 113 are located above the first partition 12. They are used to prevent the main body 11 of the dividing block from colliding with the welding protrusion when it moves upward after welding. The interference avoidance surfaces 113 are located at the upper end of the first inclined surface 111 and are partially frustoconical in shape, with the upper diameter being larger than the lower diameter.

[0048] In this embodiment, as Figure 1 As shown, the first partition 12 is attached to the second inclined surface 112 and extends upward beyond the limit line 114, and protrudes from the limit line 114, thus ensuring that the purpose of pressing the copper busbar group unit can be better achieved.

[0049] In this embodiment, as Figure 1As shown, the first dividing block includes an upper tilting unit 121 and a lower tilting unit 122. The lower tilting unit 122 extends and tilts from bottom to top towards the side of the copper busbar on the same side, and the upper tilting unit 121 extends and tilts from top to bottom towards the side of the copper busbar on the same side. The upper tilting unit 121 and the lower tilting unit 122 intersect. In this embodiment, the upper tilting unit 121 includes a first conical surface in the shape of a triangle, and the lower tilting unit 122 includes a second conical surface and a third conical surface in the shape of a triangle. The first conical surface is arranged symmetrically on the left and right along the intersection line of the second conical surface and the third conical surface. The upper and lower tilting units facilitate the up and down movement of the main body 11 of the dividing block.

[0050] In this embodiment, as Figure 3 As shown, the downward tilting unit 122 is provided with a V-shaped protrusion 1221 to facilitate the downward insertion of the main body 11 of the dividing block. It includes the intersection of a second cone surface and a third cone surface. The second cone surface and the third cone surface are arranged symmetrically about the center line of the V-shaped protrusion 1221 to facilitate the downward movement of the dividing block 1 as a whole.

[0051] like Figures 4-9 As shown, the present invention also provides a welding clamping fixture, which, in addition to the above-mentioned dividing block 1, also includes a gripper 2 and a sliding mechanism 3;

[0052] The clamp 2 includes a first clamp and a second clamp located on both sides of the wire divider block. The first clamp includes a rod 21 arranged in the radial direction of the flat wire motor disc and a second support connection 22 arranged at one end of the rod 21. The rod 21 is provided with a plurality of clamping grooves 211 at intervals on the side facing the wire divider block 1. During welding, the clamping grooves 211 are used to clamp and limit two radially adjacent copper busbars to be welded.

[0053] The sliding mechanism 3 is used to drive the first and second grippers to move toward each other, thereby getting closer to the gripper 2 and clamping the multiple copper busbar group units 41.

[0054] The welding clamping fixture of the present invention abuts against the sides of two adjacent sets of copper busbars circumferentially through a limiting surface or limiting line, and then clamps multiple copper busbar groups by cooperating with the first partition block, clamping groove and protrusion. Then, the sliding mechanism drives the two jaws to move towards each other to clamp multiple sets of copper busbar groups. When the dividing block moves downward, the first partition block is inserted into the welding gap between two radially adjacent copper busbar terminals, ensuring that the two copper busbar terminals are clamped and that there is a suitable welding gap. This ensures that no axial movement occurs during welding, ensures welding quality, and also effectively prevents welding spatter.

[0055] In this embodiment, as Figure 3 , 4As shown in Figure 9, the sliding mechanism 3 includes two first bases 31 fixedly mounted below the gripper 2, and a second base 32 fixedly mounted on the dividing block 1. The dividing block 1 also includes a first support connection part 13 at its end connected to the second base 32. The gripper 2 also includes a second support connection part 22 at its end connected to the first base 31. The first base 31 and the second base 32 are connected as a whole by a sliding positioning pin 33 passing through them laterally. The end of the second base 32 away from the dividing block 1 is fixedly mounted on the assembly base plate 34. The assembly base plate 34 is fixedly mounted on the robotic arm. The robotic arm drives the sliding mechanism 3, the gripper 2 and the dividing block 1 to move as a whole, thereby bringing them to the copper busbar assembly unit 4. The first base 31 and the second base 32 are provided with independent drive cylinders (not shown in the figure) at both ends. The drive cylinders drive the first bases 31 on both sides to move towards the second base 32 in the middle at the same speed along the sliding positioning pin 33, thereby driving the grippers on both sides to move towards the dividing block 1 in the middle position and clamp the copper busbar assembly unit 41.

[0056] In this embodiment, as Figure 4 As shown, the clamping groove 211 includes a groove bottom 2111, and protrusions 212 are provided on both sides of the groove bottom 2111. There are three protrusions 212, which are approximately conical. The protrusions 212 are used to limit and clamp the two copper busbars of a single copper busbar group unit 41 during welding. The groove bottom 2111 is provided with a second partition block 2112 corresponding to the first partition block. The groove bottom 2111 is arc-shaped, and the second partition block 2112 is a straight line connecting the left and right groove bottoms 2111. The second partition block 2112 ensures that there is a suitable welding gap between the two copper busbar terminals. During welding, the second partition block 2112 is inserted between the two radially adjacent copper busbars being welded.

[0057] like Figures 10-11 As shown, the present invention also provides a positioning method for a welding clamping fixture, comprising the following steps:

[0058] S1. The welding clamping fixture (including the dividing block 1) is driven to move downward by the robotic arm. The main body 11 of the dividing block moves downward to separate two adjacent copper busbars in the circumferential direction. At the same time, eight first dividing blocks are inserted into the welding gap between the terminals of two adjacent copper busbars in the radial direction.

[0059] S2. By manipulating the sliding mechanism 3, the first and second grippers move towards the middle dividing block 1 at the same time. The limit line 114 abuts against the side of the two adjacent copper busbars on the circumference. Then, through the cooperation with the first dividing block, the clamping groove 211 and the protrusion 212, the multiple copper busbar group units 41 are clamped.

[0060] S3. After welding, manipulate the sliding mechanism 3 to move the first and second grippers away from the wire splitter block 1. In addition, the wire splitter block 1 exits upward from the copper wire terminal welding protrusion through the interference avoidance surface set on the side.

[0061] In this embodiment, the weld gap between the two copper wire terminals in the copper busbar assembly unit 41 is 0.2–0.5 mm, and its size is inspected by a laser vision inspection module to determine if it is acceptable. Normally, after clamping the two copper busbar terminals, their upper and lower ends are flush. If the laser vision inspection module detects that the upper and lower ends are not flush, a push plate (not shown in the figure) can be used to press the end faces of the two copper busbar terminals to the same height, making them flush along the height direction.

[0062] The positioning method of the welding clamping fixture of the present invention firstly positions the copper busbar group unit from the middle by moving the dividing block downwards, and then clamps multiple copper busbar group units simultaneously by the first and second clamping jaws that cooperate with it. The limiting surface or limiting line abuts against the side of two adjacent groups of copper busbars circumferentially, and then clamps multiple copper busbar group units by cooperating with the first dividing block, the clamping groove and the protrusion. This results in higher welding accuracy.

[0063] The above-described invention merely illustrates implementation methods of the present invention and should not be construed as limiting the scope of the invention patent, nor as imposing any form of limitation on the structure of the embodiments of the present invention. It should be noted that those skilled in the art can make various changes and improvements without departing from the concept of the embodiments of the present invention, and these all fall within the protection scope of the embodiments of the present invention.

Claims

1. A line divider block, characterized in that: It includes a main body (11) of the dividing block and a first dividing part (12); The main body (11) of the wire dividing block is arranged along the radial direction of the flat wire motor disc; The main body of the dividing block (11) is provided with limiting surfaces or limiting lines on both sides, and the limiting surfaces or limiting lines are used to abut against the sides of two adjacent sets of copper busbars in the circumferential direction. The first partition (12) is provided on at least one side of the main body of the wire splitting block (11) and protrudes circumferentially from the main body of the wire splitting block (11); the first partition (12) includes a plurality of first partition blocks arranged radially at intervals, the first partition blocks being used to insert into the welding gap between two radially adjacent copper busbar terminals when the wire splitting block (1) moves downward; The left and right sides of the main body of the splitter block (11) also include a second inclined surface (112). The second inclined surface (112) extends upward from the lower end of the main body of the splitter block (11) towards the side of the copper busbar on the same side and is inclined, and is connected to the limiting surface or limiting line. The upper left and right sides of the main body of the dividing block (11) are provided with interference avoidance surfaces (113). The interference avoidance surfaces (113) are located above the first partition (12) and are used to prevent the main body of the dividing block (11) from colliding with the welding protrusion when the main body of the dividing block (11) moves upward after welding. The interference avoidance surface (113) is located at the upper end of the first inclined surface (111). The interference avoidance surface (113) is a local frustum shape with the upper diameter being larger than the lower diameter. The first dividing block includes an upper inclined unit (121) and a lower inclined unit (122). The lower inclined unit (122) extends and tilts from bottom to top toward the side of the copper busbar on the same side. The upper inclined unit (121) extends and tilts from top to bottom toward the side of the copper busbar on the same side. The upper inclined unit (121) and the lower inclined unit (122) intersect. The downward tilting unit (122) is provided with a V-shaped protrusion (1221) for facilitating the downward insertion of the main body (11) of the dividing block.

2. A splitter block as described in claim 1, characterized in that: The left and right sides of the main body of the branch block (11) also include a first inclined surface (111). The first inclined surface (111) extends downward from the upper end of the main body of the branch block (11) towards the side of the copper busbar on the same side and is inclined, and is connected to the limiting surface or limiting line.

3. A splitter block as described in claim 1, characterized in that: The first partition (12) is attached to the second inclined surface (112) and extends upward beyond the limiting surface or limiting line, and protrudes from the limiting surface or limiting line.

4. A welding clamping fixture, characterized in that: It includes the dividing block as described in any one of claims 1 to 3, and further includes a gripper (2) and a sliding mechanism (3); The clamp (2) includes a first clamp and a second clamp located on both sides of the wire splitter block. The first clamp includes a rod (21) arranged in the radial direction of the flat wire motor disc and a second support connection (22) arranged at one end of the rod (21). The rod (21) is provided with a plurality of clamping grooves (211) at intervals on the side facing the wire splitter block (1). During welding, the clamping grooves (211) are used to clamp and limit two radially adjacent copper busbars being welded. The sliding mechanism (3) is used to drive the first and second grippers to move toward each other, thereby clamping multiple copper busbar units (41).

5. The welding clamping fixture as described in claim 4, characterized in that: The clamping groove (211) includes a groove bottom (2111), and protrusions (212) are provided on both sides of the groove bottom (2111). The protrusions (212) are used to limit and clamp the two copper bars of a single copper bar group unit (41) during welding. The groove bottom (2111) is provided with a second partition block (2112) corresponding to the first partition block. During welding, the second partition block (2112) is inserted between two radially adjacent copper bars being welded.

6. A positioning method using the welding clamping fixture as described in claim 5, characterized in that, Includes the following steps: The dividing block (1) moves downward, and the dividing block body (11) moves downward to separate two adjacent copper busbars in the circumferential direction. At the same time, multiple first dividing blocks are inserted into the welding gap between the terminals of two adjacent copper busbars in the radial direction. By manipulating the sliding mechanism (3), the first and second grippers move towards the middle dividing block (1) simultaneously. The clamping surfaces or lines abut against the sides of the two adjacent copper busbars, and the multiple copper busbar groups (41) are clamped by cooperating with the first dividing block, the clamping groove (211) and the protrusion (212). After welding, the sliding mechanism (3) is manipulated to move the first and second grippers away from the wire divider block (1), and the wire divider block (1) is pulled out upward from the copper wire terminal welding protrusion by the side-mounted interference avoidance surface (113).

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