Flat wire 3D forming device and stator wire forming system

Abstract

The invention provides a flat wire 3D forming device and a stator wire forming system, and belongs to the field of automobile intelligent manufacturing. The flat wire 3D forming device comprises a mold pressing tower forming mechanism, a 2D flat wire feeding mechanism and a 3D flat wire receiving mechanism; the mold pressing tower forming mechanism comprises lower mold assemblies of different models, upper mold assemblies of different models, a mold pressing driving assembly, a sliding mounting plate, a lifting switching assembly and a fixed back plate frame. The lifting switching assembly drives the sliding mounting plate to integrally ascend and descend so that different models of molds can be switched at machining stations, and the mold pressing driving assembly drives the lower mold assembly and the upper mold assembly on the corresponding side to achieve mold pressing 3D forming of the flat wire. 3D compression molding forming can be conducted on 2D flat wires of different models and specifications in batches through the compression molding tower forming mechanism, the mold switching speed is high, intelligent batch production is achieved in cooperation with the 2D flat wire feeding mechanism and the 3D flat wire receiving mechanism, the production efficiency and the qualified rate are high, and application and popularization in the field of intelligent automobile manufacturing are facilitated.

Description

Technical Field

[0001] The present invention belongs to the field of intelligent manufacturing of automobiles, and particularly relates to a flat wire 3D forming device and a stator wire forming system. Background Art

[0002] The new energy vehicle industry is booming at an unprecedented speed. As one of the core components of new energy vehicles, the performance of the drive motor directly affects the power performance, economy and cruising range of the whole vehicle. In recent years, flat wire motors have gradually become the first choice for new energy vehicle drive motors due to their high power density, high efficiency, low noise and good heat dissipation performance. However, in the manufacturing process of flat wire motors, the wiring, pin, I-pin, Hair-pin, X-pin of the stator, which are collectively referred to as stator wires in this application, see Figure 1 , how to efficiently bend flat wire raw materials into 2D flat wires and then process them into 3D shapes is a technical problem in the field of intelligent or automated manufacturing. The traditional manual bending with tools not only has low efficiency, but also is difficult to guarantee the forming angle, which not only increases the manufacturing cost, but also affects the performance and reliability of the motor. Therefore, developing an efficient and precise intelligent 3D forming processing device for 2D flat wires is of great significance for improving the manufacturing quality and production efficiency of flat wire motors. Summary of the Invention

[0003] In order to overcome the deficiencies of the prior art, the purpose of the present invention is to provide a flat wire 3D forming device and a stator wire forming system, which can solve the above problems.

[0004] A flat wire 3D forming device includes a die pressing tower forming mechanism. The die pressing tower forming mechanism includes a plurality of lower die components of different models installed on a lower die mounting plate, a plurality of upper die components of different models installed on an upper die mounting plate, a die pressing drive component, a sliding mounting plate, a lifting and switching component, and a fixed back plate frame; the lifting and switching component drives the overall lifting of the sliding mounting plate to realize the switching of different models of dies at the processing position, and the die pressing drive component drives the corresponding lower die component and upper die component on the same side to realize the die pressing 3D forming of the flat wire.

[0005] Furthermore, the lower die component includes a lower die outer guide block, a lower die inner guide block and a wire leg support groove block arranged on a lower die bottom plate; a die knife groove for accommodating a lower die knife is formed at an interval between the lower die outer guide block and the lower die inner guide block; a wire leg support groove block is arranged at the feeding end in front of the lower die outer guide block and the lower die inner guide block for supporting and guiding the wire legs of the flat wire to be processed; multiple groups of the lower die components are connected to the lower die mounting plate through corresponding lower die mounting frames.

[0006] Further, the upper die assembly includes an upper die bottom plate, an upper die cutter, and an upper die limit guiding pin assembly; an upper cutter groove and a plurality of guiding and limiting holes are formed in the upper die bottom plate, the upper die cutter is fixedly embedded in the upper cutter groove, the upper die limit guiding pin assembly is inserted into the guiding and limiting holes, and the bottom end of the pin of the upper die limit guiding pin assembly is embedded in the corresponding guiding hole of the lower die assembly; multiple groups of the upper die assemblies are connected to the upper die mounting plate through corresponding upper die mounting brackets.

[0007] Further, the flat wire 3D forming device further includes a 2D flat wire feeding mechanism and a 3D flat wire receiving mechanism arranged along the material line conveying direction. The 2D flat wire feeding mechanism clamps and feeds the single leg of the 2D flat wire, and the 3D flat wire receiving mechanism is used for clamping and receiving the 3D flat wire processed and formed by the molding tower forming mechanism with both legs.

[0008] Further, the flat wire 3D forming device further includes a module gauge for regularly correcting the molding accuracy.

[0009] This application also provides a stator wire forming system, which includes a flat wire feeding module, a wire cutting module, a flat wire 2D forming device, a flat wire 3D forming device, a wire type optical detection mechanism, a carbon brush detection mechanism, and a blanking and receiving mechanism.

[0010] Compared with the prior art, the beneficial effects of the present invention are as follows: Through the molding tower forming mechanism, this application can batch perform 3D molding on 2D flat wires of different model specifications. The switching speed of different model molds is fast, meeting the high-efficiency 3D forming requirements. And in cooperation with the 2D flat wire feeding mechanism and the 3D flat wire receiving mechanism, intelligent batch production is realized, with high production efficiency and qualified rate, which is convenient for popularization and application in the field of flat wire motors involved in automotive intelligent manufacturing. Description of the Drawings

[0011] Figure 1 It is a diagram showing different examples of the flat wire from straight line through 2D forming to 3D forming; Figure 2 It is a schematic diagram of the molding tower forming mechanism; Figure 3 It is an exploded schematic diagram of the lower die assembly and the upper die assembly; Figure 4 It is a schematic diagram of the lower die cutter and the upper die cutter; Figure 5 It is a schematic diagram of the flat wire 3D forming device.

[0012] In the figure, 100. Molding tower forming mechanism; 110. Lower die assembly; 111. Lower die mounting bracket; 112. Lower die bottom plate; 113. Outer lower die guide block; 114. Inner lower die guide block; 115. Wire leg support groove block; 116. Lower die cutter; 117. Die cutter floating assembly; 118. Lower die guide block; 119. Stock support block; 120. Upper die assembly; 121. Upper die mounting bracket; 122. Upper die bottom plate; 123. Upper die cutter; 124. Upper die limit guide pin assembly; 130. Lower die mounting plate; 140. Upper die mounting plate; 150. Mold pressing drive assembly; 160. Sliding mounting plate; 170. Lifting and switching assembly; 180. Fixed back plate frame; 200. 2D flat wire feeding mechanism; 300. 3D flat wire receiving mechanism; 400. Conveyor line; 500. Module gauge. Detailed implementation manners

[0013] To make the objectives, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Apparently, the described embodiments are some but not all of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0014] Flat wire 3D forming device A flat wire 3D forming device, the flat wire 3D forming device includes a mold pressing tower forming mechanism 100, and the mold pressing tower forming mechanism 100 includes a plurality of lower die assemblies 110 of different models installed on a lower die mounting plate 130, a plurality of upper die assemblies 120 of different models installed on an upper die mounting plate 140, a mold pressing drive assembly 150, a sliding mounting plate 160, a lifting and switching assembly 170, and a fixed back plate frame 180.

[0015] Mold pressing principle: The lifting and switching assembly 170 drives the overall lifting of the sliding mounting plate 160 to realize the switching of different models of molds at the processing position, and the mold pressing drive assembly 150 drives the corresponding lower die assembly 110 and upper die assembly 120 on the corresponding side to realize the 3D forming of the flat wire by mold pressing.

[0016] Among them, the lower die assembly 110 includes an outer lower die guide block 113, an inner lower die guide block 114, and a wire leg support groove block 115 provided on a lower die bottom plate 112; a die knife groove for accommodating a lower die knife 116 is formed at an interval between the outer lower die guide block 113 and the inner lower die guide block 114; a wire leg support groove block 115 is provided at the feeding end in front of the outer lower die guide block 113 and the inner lower die guide block 114 for supporting and guiding the wire legs of the flat wire to be processed; multiple groups of the lower die assemblies 110 are connected to a lower die mounting plate 130 through corresponding lower die mounting brackets 111.

[0017] Specifically, the lower surface of the lower die bottom plate 112 is connected to the top surface of a transfer horizontal plate of the lower die mounting bracket 111, and the back surface of a transfer vertical plate of the lower die mounting bracket 111 is mounted on the front surface of the lower die mounting plate 130.

[0018] The lower die knife 116 is embedded into the die knife groove between the outer lower die guide block 113 and the inner lower die guide block 114 through a set of die knife floating assemblies 117.

[0019] The die knife floating assembly 117 includes a floating support block and a floating spring. The upper part of the floating support block is grooved and fitted with the lower part of the lower die knife 116.

[0020] Further, a guide hole is opened on the inner lower die guide block 114, and a guide slot hole is opened on the wire leg support groove block 115. A set of lower die guide blocks 118 are installed in the guide slot holes of the wire leg support groove block 115.

[0021] Further, two material support blocks 119 are further provided on the front end wall of the wire leg support groove block 115 for pre-supporting and guiding the incoming flat wire. The groove shapes of the two material support blocks 119 are the same as the two groove shapes opened on the wire leg support groove block 115.

[0022] Among them, the upper die assembly 120 includes an upper die bottom plate 122, an upper die knife 123, and an upper die limit guide pin assembly 124; an upper knife groove and a plurality of guide limit holes are opened on the upper die bottom plate 122, the upper die knife 123 is fixedly embedded into the upper knife groove, the upper die limit guide pin assembly 124 is inserted into the guide limit holes, and the bottom end of the pin of the upper die limit guide pin assembly 124 is embedded into the corresponding guide holes of the lower die assembly 110; multiple groups of the upper die assemblies 120 are connected to an upper die mounting plate 140 through corresponding upper die mounting brackets 121.

[0023] Specifically, the upper surface of the upper die bottom plate 122 is connected to the bottom surface of a transfer horizontal plate of the upper die mounting bracket 121, and the back surface of a transfer vertical plate of the upper die mounting bracket 121 is mounted on the front surface of the upper die mounting plate 140.

[0024] Specifically, guiding holes are provided on both the online leg bracket block 115 and the lower die guiding block 118 for accommodating the lower section of the pin of the upper die limit guiding pin assembly 124.

[0025] The die edges of the upper die cutter 123 and the lower die cutter 116 are matched, and the middle part of the 2D flat wire therebetween is formed by extrusion to obtain a 3D turned head as shown in the rightmost figure. Figure 1 the rightmost illustrated 3D turned head.

[0026] The two die pressing drive assemblies 150 and one lifting and switching assembly 170 are in the form of a motor screw mechanism, a cylinder sliding mechanism or a linear motor drive.

[0027] This application preferably adopts a motor or a cylinder screw mechanism. The screw nut is connected to the mounting plate to be lifted. Of course, other forms can also be adopted.

[0028] Further, referring to Figure 5 , the flat wire 3D forming device further includes a 2D flat wire feeding mechanism 200 and a 3D flat wire receiving mechanism 300 arranged along the feeding direction of the material line. The 2D flat wire feeding mechanism 200 clamps and feeds a single leg of the 2D flat wire, and the 3D flat wire receiving mechanism 300 is used for clamping and receiving the 3D flat wire processed and formed by the die pressing tower forming mechanism 100 with both legs.

[0029] In a specific example, the 2D flat wire feeding mechanism 200 and the 3D flat wire receiving mechanism 300 share a conveyor line 400. Preferably, a set of linear motors is adopted, and the two are installed on different motor movers.

[0030] Further, referring to Figure 5 , the flat wire 3D forming device further includes a module gauge 500 for regularly calibrating the die pressing accuracy.

[0031] Stator wire forming system A stator wire forming system, not shown in the figure, the stator wire forming system includes a flat wire feeding module, a wire cutting module, a 2D flat wire forming device, the flat wire 3D forming device according to the foregoing, a wire type optical detection mechanism, a carbon brush detection mechanism and a blanking and receiving mechanism.

[0032] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements for some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A flat wire 3D forming device, characterized in that: The flat wire 3D molding device comprises a molding tower molding mechanism (100), the molding tower molding mechanism (100) comprising a plurality of lower mold assemblies (110) of different models mounted on a lower mold mounting plate (130), a plurality of upper mold assemblies (120) of different models mounted on an upper mold mounting plate (140), a molding drive assembly (150), a sliding mounting plate (160), a lifting and lowering switching assembly (170), and a fixed back plate frame (180); The lifting switching assembly (170) drives the sliding mounting plate (160) to lift as a whole to achieve the switching of different types of molds at the processing position, and the molding driving assembly (150) drives the lower mold assembly (110) and the upper mold assembly (120) on the corresponding side to achieve the molding 3D molding of the flat wire.

2. The flat wire 3D forming device according to claim 1, characterized in that: The lower mold assembly (110) comprises a lower mold outer guide block (113), a lower mold inner guide block (114) and a wire leg bracket block (115) arranged on a lower mold base plate (112); a die knife groove for accommodating a lower mold knife (116) is formed between the lower mold outer guide block (113) and the lower mold inner guide block (114); a wire leg bracket block (115) is arranged at a feed end in front of the lower mold outer guide block (113) and the lower mold inner guide block (114) for supporting and guiding the wire legs of the flat wire to be processed; multiple groups of the lower mold assemblies (110) are connected to the lower mold mounting plate (130) via corresponding lower mold mounting frames (111).

3. The flat wire 3D forming device according to claim 2, characterized in that: The lower die cutter (116) is embedded in the die cutter groove between the lower die outer guide block (113) and the lower die inner guide block (114) via a set of die cutter floating components (117).

4. The flat wire 3D forming device according to claim 2, characterized in that: The upper mold assembly (120) comprises an upper mold base plate (122), an upper mold knife (123) and an upper mold limit guide pin assembly (124); an upper knife groove and a plurality of guide limit holes are provided on the upper mold base plate (122); the upper mold knife (123) is fixedly embedded in the upper knife groove; the upper mold limit guide pin assembly (124) is inserted into the guide limit hole; and the pin bottom end of the upper mold limit guide pin assembly (124) is embedded in the corresponding guide hole of the lower mold assembly (110); a plurality of groups of the upper mold assemblies (120) are connected to the upper mold mounting plate (140) via corresponding upper mold mounting frames (121).

5. The flat wire 3D forming device according to claim 2, characterized in that: The two molded drive components (150) and the one lifting and lowering switching component (170) include a motor screw mechanism, a cylinder sliding mechanism or a linear motor drive.

6. The flat wire 3D forming device according to claim 1, characterized in that: The flat wire 3D forming device further comprises a 2D flat wire feeding mechanism (200) and a 3D flat wire receiving mechanism (300) arranged along the material line conveying direction, the 2D flat wire feeding mechanism (200) clamping the 2D flat wire for single-leg feeding, and the 3D flat wire receiving mechanism (300) for double-leg clamping to receive the 3D flat wire formed by the molding tower forming mechanism (100).

7. The flat wire 3D forming device according to claim 1, characterized in that: The flat wire 3D molding device also includes a module gauge (500) for regularly calibrating molding accuracy.

8. A stator wire forming system, characterized in that: The stator wire forming system includes a flat wire feeding module, a wire cutting module, a flat wire 2D forming device, a flat wire 3D forming device according to any one of claims 1-7, a linear optical detection mechanism, a carbon brush detection mechanism and a material feeding and receiving mechanism.

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