New energy automobile flat wire motor stator winding process

Abstract

The invention discloses a new energy automobile flat wire motor stator winding process, which comprises the following steps of: inserting insulation paper into a wire slot of a stator core; the flat wire is bent and formed after being cut; inserting the bent and formed flat wire into a wire slot of the stator core; twisting the end part of the flat wire; cutting and cleaning the end parts of the adjacent flat wires; the flat wire end part is subjected to laser welding, the flat wire end part is twisted and then is cut flat and cleaned, the flatness of the flat wire end part can be ensured by cutting flat, and impurities adhered to the flat wire end part can be removed by cleaning, so that the subsequent welding quality is effectively improved, and the overall performance of a final motor is further ensured.

Description

Technical Field

[0001] The present invention relates to the field of motor production, and in particular to a stator winding process for a flat wire motor of a new energy vehicle. Background Art

[0002] The flat wire motor is a new type of motor and is widely used in fields such as new energy vehicles. The flat wire stator is an important part of the flat wire motor. The flat wire stator mainly includes a flat wire winding, a stator core, and an insulating component. Compared with the round wire winding, the flat wire winding can be arranged more closely in the stator slot, greatly improving the slot fill factor, and thus enhancing the output power of the motor.

[0003] At present, the winding methods of flat wire motors mainly include two methods: hairpin winding and continuous winding. Among them, the hairpin winding has a high slot fill factor and regular ends, which is conducive to heat dissipation and is suitable for large-scale automated production; during the production process, the formed flat wire is inserted into the slots of the stator core, and then the ends of the hairpin winding are turned and welded. However, during actual production, the ends of the windings to be welded are not flat, which is likely to affect the final welding quality and thus the performance of the flat wire motor, and needs to be further improved. Summary of the Invention

[0004] In order to further improve the welding quality, the present application provides a stator winding process for a flat wire motor of a new energy vehicle.

[0005] The present application provides a stator winding process for a flat wire motor of a new energy vehicle, adopting the following technical solutions: A stator winding process for a flat wire motor of a new energy vehicle includes the following steps: S1, inserting insulating paper into the slots of the stator core; S2, cutting and bending the flat wire into shape; S3, inserting the bent flat wire into the slots of the stator core; S4, twisting the ends of the flat wire; S5, cutting and cleaning the ends of adjacent flat wires; S6, laser welding the ends of the flat wire.

[0006] Optionally, in step S6, a laser welding device is used to weld the ends of the flat wire. The laser welding device includes a chassis, a positioning table is rotatably connected to the chassis, the positioning table has a positioning portion for positioning the stator core, an installation frame is fixedly arranged above the chassis, a laser welder is installed on the installation frame, and a nozzle is arranged at the bottom of the installation frame corresponding to the flat wire ends of the stator core, and the nozzle is connected to a high-pressure gas source.

[0007] Optionally, the mounting bracket includes an integrally provided mounting strip and a ring strip. The mounting strips are symmetrically distributed along the radial direction, and the ring strip connects each mounting strip. A sliding seat is slidably connected to the mounting strip along the radial direction. A vertical lifting cylinder is provided on the sliding seat, and the laser welder is installed at the output end of the lifting cylinder.

[0008] Optionally, a mounting post is provided at the center of the mounting bracket. A return spring for connecting the two is provided between the sliding seat and the mounting post. The return spring is used to drive the sliding seat to move radially inwards for reset. A driving mechanism is provided on the mounting bracket to drive the sliding seats on each mounting strip to move outwards synchronously.

[0009] Optionally, the driving mechanism includes a vertical cylinder and a driving rod. The vertical cylinder is installed on the mounting post and drives the driving rod to lift vertically. A first wedge block is fixedly provided on the driving rod, and a second wedge block corresponding to the first wedge block is provided on the sliding seat. The first wedge block and the second wedge block have inclined surfaces for mutual abutment. When the first wedge block moves downwards, it drives the second wedge block to move outwards away from the center of the circle.

[0010] Optionally, the sliding seat has an extension rod extending towards the mounting post. A switch button for controlling the operation of the air nozzle is provided on the mounting post corresponding to the extension rod. After the sliding seat moves inwards and resets under the action of the return spring, the extension rod presses the switch button to open the air nozzle and blow air. The air nozzles are evenly distributed on the bottom wall of the ring strip.

[0011] Optionally, an adjusting block is rotatably connected to the mounting post, and the switch button is provided on the adjusting block.

[0012] Optionally, the rotation center line of the adjusting block is horizontal and eccentrically arranged.

[0013] Optionally, the positioning portion includes a positioning block and a driving block that are vertically slidably connected to the positioning table. The positioning block is used to fit with the positioning groove on the outer periphery of the stator core. A sliding groove for the driving block to slide vertically is provided on the positioning table. A compression spring is provided at the top of the sliding groove to drive the driving block to move upwards and reset to protrude out of the sliding groove. A linkage member for driving the two to move in opposite directions is provided between the driving block and the positioning block.

[0014] Optionally, the linkage member includes a connecting rod. The middle of the connecting rod is rotatably connected inside the positioning table. One end of the connecting rod is movably hinged to the driving block, and the other end is movably hinged to the positioning block.

[0015] In summary, the present application includes at least one of the following beneficial technical effects: 1. After the end of the flat wire is twisted, it is then flattened and cleaned. Flattening can ensure the flatness of the end of the flat wire, and cleaning can remove impurities adhering to the end of the flat wire, thereby effectively improving the quality of subsequent welding and further ensuring the overall performance of the final motor. 2. A unique welding device is used to weld the end of the flat wire. The stator core is positioned through the positioning part on the positioning table to achieve circumferential linkage. During welding, the positioning table can be driven to rotate to achieve rapid switching of the welding area, improving the welding efficiency. 3. The laser welder can be adjusted radially to slide to switch the radial welding position. The vertical cylinder drives the driving rod to move downward, and the sliding seat is driven to move outward by the abutment of the inclined surface to adjust the position of the laser welder. The structure is simple and convenient. When the sliding seat is in the initial position, it presses the switch button under the action of the return spring, making the air nozzle in the open state, realizing automatic cleaning before welding. After completing the welding on one radial path, the sliding seat resets to the initial position and the air nozzle is opened again to realize air drying of the welding area, improving the welding efficiency, realizing the multi-purpose of the air nozzle. During welding, the extension rod does not press the switch button, and the air nozzle is in the closed state, well realizing the automatic opening and closing of the air nozzle, achieving a certain energy-saving purpose. Description of the Drawings

[0016] Figure 1 is the flowchart of the embodiment of the present application.

[0017] Figure 2 is the structural diagram of the welding device in the embodiment of the present application.

[0018] Figure 3 is the bottom view of the mounting bracket in the embodiment of the present application.

[0019] Figure 4 is the structural diagram of the positioning table and the stator core in the embodiment of the present application.

[0020] Figure 5 is Figure 4 the enlarged view of part A in

[0021] Description of the Reference Numerals: 1. Stator core; 2. Laser welder; 3. Base frame; 4. Positioning table; 5. Driving motor; 6. Mounting bracket; 7. Mounting strip; 8. Ring strip; 9. Air nozzle; 10. Sliding seat; 11. Guide groove; 12. Lifting cylinder; 13. Mounting column; 14. Return spring; 15. Vertical cylinder; 16. Driving rod; 17. Top frame; 18. First wedge block; 19. Second wedge block; 20. Inclined surface; 21. Extension rod; 22. Adjusting block; 23. Switch button; 24. Boss; 25. Positioning block; 26. Driving block; 27. Positioning groove; 28. Chute; 29. Compression spring; 30. Connecting rod; 31. Slot. Detailed Embodiment

[0022] The following is combined with the attachedFigures 1 - 5 Further detailed description is made to this application.

[0023] A winding process for the flat wire motor stator of a new energy vehicle, as Figure 1 shown, mainly includes the following steps: S1, inserting insulating paper; Cut the insulating paper into a shape adapted to the slot of the stator core 1, and insert the insulating paper into the slot of the stator core 1.

[0024] S2, cutting, bending and forming the flat wire; Remove the paint film of the flat wire by laser, then cut the flat wire into a suitable length, and then bend and form it so that the flat wire has a hairpin structure.

[0025] S3, inserting the flat wire into the slot; Insert the formed flat wire into the profiling tooling, and then insert the coils with all hairpin structures as a whole into the slots of the stator core 1.

[0026] S4, twisting the end of the flat wire; First flare the end of the flat wire, and then twist it to complete the turning head process.

[0027] S5, trimming and cleaning the end of the flat wire; Trim and clean the uneven parts of the adjacent ends of the flat wire to be welded, so that the adjacent ends of the flat wire are kept flat and clean.

[0028] S6, laser welding; Use the laser welder 2 to weld the adjacent ends of the flat wire to achieve the electrical connection of the flat wire winding.

[0029] As Figure 2 shown, in step S6, a laser welding device is used to weld the ends of the flat wire. The laser welding device includes a chassis 3. A positioning table 4 is rotatably connected to the chassis 3. A positioning portion for positioning the stator core 1 is provided on the positioning table 4. During actual use, the stator core 1 to be welded is placed on the positioning table 4 for positioning. A driving motor 5 for driving the circumferential rotation of the positioning table 4 is provided at the bottom of the chassis 3. In addition, a mounting frame 6 is provided at the top of the chassis 3. A laser welder 2 is mounted on the mounting frame 6. The ends of the flat wire below are welded by the laser welder 2.

[0030] As Figure 2 and Figure 3As shown, the mounting bracket 6 includes an integrally provided mounting strip 7 and a ring strip 8. The length direction of the mounting strip 7 is arranged radially. A plurality of mounting strips 7 are evenly distributed around the circumference. The ring strip 8 connects and fixes each mounting strip 7. In this embodiment, there are two symmetrically arranged mounting strips 7. In other embodiments, the number of mounting strips 7 can also be set to 4, 6, etc. On the bottom wall of the ring strip 8, there is an air nozzle 9 facing the end of the flat wire. The air nozzle 9 is connected to a high-pressure air source through a pipeline. The high-pressure air source can be an air compressor. A solenoid valve for opening and closing is provided on the pipeline. By controlling the opening and closing of the solenoid valve, the opening and closing of the air nozzle 9 can be achieved. In this way, the end of the flat wire below can be blown and cleaned by means of the air nozzle 9, and the impurities on the end of the flat wire can be removed to improve the final welding quality.

[0031] As Figure 2 and Figure 3 shown, a sliding seat 10 is slidably connected to the mounting strip 7 along its length direction. A guide groove 11 for slidably connecting the sliding seat 10 is provided on the mounting strip 7. A lifting cylinder 12 is fixedly arranged at the bottom of the sliding seat 10. The laser welder 2 is fixedly installed at the end of the lifting cylinder 12. Welding is achieved by driving the laser welder 2 to move vertically up and down by the lifting cylinder 12. A mounting column 13 is fixedly arranged at the center of the mounting bracket 6. A return spring 14 for connecting the two is arranged between the sliding seat 10 and the mounting column 13. The return spring 14 is used to drive the sliding seat 10 to move radially inwards for reset. In addition, a driving mechanism for driving the sliding seats 10 on each mounting strip 7 to move outwards synchronously is provided on the mounting bracket 6. In actual welding, by driving each sliding seat 10 to move outwards synchronously, welding of the ends of all flat wires on the radial path can be achieved. After completing the welding of the ends of the flat wires on one radial path, the stator core 1 is driven to rotate circumferentially to switch the angle and then welding is carried out. In this way, welding of all the ends of the flat wires can be achieved by cycling, and the welding efficiency is high.

[0032] As Figure 2 shown, the driving mechanism includes a vertical cylinder 15 and a driving rod 16. A top bracket 17 for installing the vertical cylinder 15 is fixedly arranged on the top of the mounting bracket 6. The vertical cylinder 15 faces downwards vertically. The driving rod 16 is fixed at the output end of the vertical cylinder 15. The vertical cylinder 15 drives the driving rod 16 to move vertically up and down. The driving rod 16 is horizontally arranged. First wedge blocks 18 are arranged at both ends of the driving rod 16. Second wedge blocks 19 corresponding to the first wedge blocks 18 are arranged on the sliding seat 10. The first wedge blocks 18 and the second wedge blocks 19 have inclined surfaces 20 for mutual abutment and matching. During the downward movement of the driving rod 16, the first wedge blocks 18 abut against the second wedge blocks 19 to drive the sliding seats 10 to move outwards synchronously in the radial direction to achieve radial synchronous adjustment of the positions. The structure is simple and the operation is convenient.

[0033] As Figure 2 and Figure 3As shown, an extension rod 21 extending toward the mounting column 13 is fixedly provided on the slide 10, and an adjustment block 22 is rotatably connected to the mounting column 13, and a switch button 23 for controlling the opening and closing of the gas nozzle 9 is provided on the adjustment block 22. When the slide 10 is moved inward and reset to the initial position under the action of the reset spring 14, the extension rod 21 presses the switch button 23 to open the gas nozzle 9, so as to realize the air blowing cleaning before welding and the air drying after welding, and effectively improve the quality and efficiency of welding. When the driving rod 16 moves downward, the slide 10 is driven to move radially outward for welding. , the end of the extension rod 21 no longer presses the switch button 23, and the air nozzle 9 is closed at this time, so as to avoid the air blowing of the air nozzle 9 during welding and affect the welding, and realize the automatic opening and closing of the air nozzle 9, so as to achieve a certain energy-saving purpose and realize the multi-purpose of the air nozzle 9. On the one hand, the air nozzle 9 can blow air to clean the end of the flat wire before welding. After completing the welding on a radial path, the driving rod 16 moves up, and the slide seat 10 moves inward and resets under the action of the reset spring 14 to open the air nozzle 9 again. At this time, the air nozzle 9 can air-dry the end of the flat wire after welding to accelerate the curing effect.

[0034] like Figure 2 As shown, the rotation axis of the adjusting block 22 is horizontally arranged and consistent with the length direction of the mounting strip 7, and the rotation axis of the adjusting block 22 is eccentrically arranged, so that in actual use, the adjusting block 22 can be rotated to adjust the position of the switch button 23. In some occasions, when the air nozzle 9 is not needed, it is only necessary to rotate the adjusting block 22 so that the position of the switch button 23 is staggered with the extension rod 21; and the adjusting block 22 is located below the driving rod 16, which can limit the travel of the downward movement of the driving rod 16 to avoid excessive downward movement of the driving rod 16. In the process of rotating the adjusting block 22, the downward movement limit position of the driving rod 16 can be adjusted synchronously, thereby meeting the welding use of stators of other different specifications, having better applicability, and realizing the multi-purpose use of the adjusting block 22.

[0035] like Figure 4 and Figure 5As shown in the figure, the top of the positioning table 4 has a boss 24 adapted to the inner hole of the stator core 1. The positioning parts on the positioning table 4 include a positioning block 25 and a driving block 26. Both the positioning block 25 and the driving block 26 are vertically slidably connected to the positioning table 4, and a linkage member for linking the reverse movement of the two is provided between the positioning block 25 and the driving block 26. Positioning grooves 27 are circumferentially distributed on the outer circumference of the stator core 1. The position of the positioning block 25 corresponds to the position of the positioning groove 27. The positioning block 25 is used to move upward and snap into the positioning groove 27 to achieve the circumferential linkage between the positioning table 4 and the stator core 1. A chute 28 for the vertical sliding of the driving block 26 is provided on the positioning table 4. A compression spring 29 is provided at the bottom of the chute 28 to drive the driving block 26 to move upward and reset to a position where its top end is higher than the top wall of the positioning table 4. The top end of the driving block 26 is used to be compressed into the chute 28 by the stator core 1. When the stator core 1 is placed on the positioning table 4 during actual use, the weight of the stator core 1 drives the end of the driving block 26 to move downward and retract into the chute 28, and then the linkage member is used to link the positioning block 25 to move upward and snap into the positioning groove 27, automatically realizing the circumferential linkage between the positioning table 4 and the stator core 1, and the operation is simple and convenient.

[0036] As Figure 4 and Figure 5 shown in the figure, the linkage member includes a connecting rod 30. The middle of the connecting rod 30 is rotatably connected inside the positioning table 4. One end of the connecting rod 30 is movably hinged to the driving block 26, and the other end is movably hinged to the driving block 26. Slots 31 for the movable hinge of the end of the connecting rod 30 are provided on the driving block 26 and the positioning block 25. The structure is simple, and the reverse linkage between the driving block 26 and the positioning block 25 is well realized.

[0037] The above are all the preferred embodiments of this application, and the protection scope of this application is not limited accordingly. Therefore, all equivalent changes made according to the structure, shape, and principle of this application should be covered within the protection scope of this application.

Claims

1. A stator winding process for a flat wire motor for a new energy vehicle, characterized in that: The following steps are involved: S1, inserting insulating paper into the wire slots of the stator core (1); S2, flat wire is cut and bent into shape; S3, inserting the bent flat wire into the wire slot of the stator core (1); S4, twisting the ends of the flat wire; S5, the ends of adjacent flat wires are cut flat and cleaned; S6, laser welding the ends of the flat wires.

2. A new energy vehicle flat wire motor stator winding process according to claim 1, characterized in that: In step S6, a laser welding device is used to weld the ends of the flat wires, the laser welding device comprising a base frame (3), a positioning platform (4) is rotatably connected to the base frame (3), the positioning platform (4) has a positioning portion for positioning the stator core (1), a mounting frame (6) is fixedly arranged above the base frame (3), a laser welder (2) is installed on the mounting frame (6), and a gas nozzle (9) is arranged at the bottom of the mounting frame (6) corresponding to the end of the flat wire of the stator core (1), and the gas nozzle (9) is connected to a high-pressure gas source.

3. A new energy vehicle flat wire motor stator winding process according to claim 2, characterized in that: The mounting frame (6) comprises an integrally arranged mounting bar (7) and a ring bar (8), wherein the mounting bars (7) are symmetrically distributed along the radial direction, the ring bar (8) connects the mounting bars (7), a slide seat (10) is slidably connected to the mounting bars (7) along the radial direction, a vertical lifting cylinder (12) is arranged on the slide seat (10), and the laser welder (2) is installed at the output end of the lifting cylinder (12).

4. A new energy vehicle flat wire motor stator winding process according to claim 3, characterized in that: The center of the mounting frame (6) is provided with a mounting column (13), a reset spring (14) connecting the slide seat (10) and the mounting column (13) is provided between the slide seat (10) and the mounting column (13), the reset spring (14) is used to drive the slide seat (10) to move radially inwards and reset, and the mounting frame (6) is provided with a driving mechanism for driving the slide seats (10) on each mounting strip (7) to move outwards synchronously.

5. A new energy vehicle flat wire motor stator winding process according to claim 4, characterized in that: The driving mechanism comprises a vertical cylinder (15) and a driving rod (16). The vertical cylinder (15) is mounted on the mounting column (13) and drives the driving rod (16) to move vertically up and down. A first wedge block (18) is fixedly arranged on the driving rod (16). A second wedge block (19) corresponding to the first wedge block (18) is arranged on the sliding seat (10). The first wedge block (18) and the second wedge block (19) have inclined surfaces (20) for abutting against each other. The first wedge block (18) moves downward to drive the second wedge block (19) to move outward away from the center of a circle.

6. A new energy vehicle flat wire motor stator winding process according to claim 5, characterized in that: The slide seat (10) is provided with an extension rod (21) extending in the direction of the mounting column (13); a switch button (23) for controlling the operation of the air nozzle (9) is arranged at a position of the mounting column (13) corresponding to the extension rod (21); after the slide seat (10) is moved inward and reset under the action of the reset spring (14), the extension rod (21) presses the switch button (23) so that the air nozzle (9) is opened and blows air; the air nozzles (9) are evenly distributed on the bottom wall of the ring strip (8).

7. A new energy vehicle flat wire motor stator winding process according to claim 6, characterized in that: An adjusting block (22) is rotatably connected to the mounting column (13), and the switch button (23) is arranged on the adjusting block (22).

8. A new energy vehicle flat wire motor stator winding process according to claim 7, characterized in that: The rotation center line of the adjustment block (22) is horizontal and eccentrically arranged.

9. A new energy vehicle flat wire motor stator winding process according to claim 2, characterized in that: The positioning portion comprises a positioning block (25) and a driving block (26) which are vertically slidably connected to the positioning platform (4); the positioning block (25) is adapted to be matched with a positioning groove (27) on the outer periphery of the stator core (1); a sliding groove (28) for the driving block (26) to slide vertically is provided on the positioning platform (4); a compression spring (29) is provided at the top of the sliding groove (28) for driving the driving block (26) to move upward and reset to the top end and pass through the sliding groove (28); and a linkage member for transmitting the reverse movement of the driving block (26) and the positioning block (25) is provided between the driving block (26) and the positioning block (25).

10. A new energy vehicle flat wire motor stator winding process according to claim 9, characterized in that: The linkage member comprises a connecting rod (30), the middle part of which is rotatably connected to the positioning platform (4), one end of which is movably hinged to the driving block (26), and the other end of which is movably hinged to the positioning block (25).

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