Flat wire 3D shaping device and stator wire shaping system

Abstract

The application 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 die assemblies of different models, upper die 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 lift as a whole to switch different models of dies at a processing position. The mold pressing driving assembly drives the lower die assembly and the upper die assembly on the corresponding side to realize 3D forming of the flat wire by mold pressing. The mold pressing tower forming mechanism can be used for batch 3D mold pressing forming of 2D flat wires of different models and specifications. The die switching speed is high. In combination with the 2D flat wire feeding mechanism and the 3D flat wire receiving mechanism, the application realizes intelligent batch production, has high production efficiency and high qualification rate, and is convenient for popularization and application in the field of automobile intelligent manufacturing.

Description

Technical Field

[0001] This invention belongs to the field of intelligent automotive manufacturing, specifically relating to a flat wire 3D forming device and a stator wire forming system. Background Technology

[0002] The new energy vehicle industry is booming at an unprecedented pace. As one of the core components of new energy vehicles, the performance of the drive motor directly affects the vehicle's power, economy, and driving range. In recent years, flat-wire motors have gradually become the preferred 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 stator wires, pins, I-pins, hair-pins, and X-pins (collectively referred to as stator wires in this application) are crucial. See [link to relevant documentation]. Figure 1 Efficiently bending flat wire raw materials into 2D flat wires and then processing them into 3D shapes is a technical challenge in the field of intelligent or automated processing. Traditional manual bending with tools is not only inefficient but also makes it difficult to guarantee the forming angle, increasing manufacturing costs and affecting motor performance and reliability. Therefore, developing an efficient, precise, and 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 shortcomings of the prior art, the present invention aims to provide a flat wire 3D forming device and a stator wire forming system, which can solve the above-mentioned problems.

[0004] A flat wire 3D forming device includes a molding tower forming mechanism. The molding tower forming mechanism includes multiple lower mold assemblies of different models mounted on a lower mold mounting plate, multiple upper mold assemblies of different models mounted on an upper mold mounting plate, a molding drive assembly, a sliding mounting plate, a lifting and switching assembly, and a fixed back plate frame. The lifting and switching assembly drives the sliding mounting plate to lift and lower as a whole to switch between different models of molds at the processing position. The molding drive assembly drives the lower mold assembly and upper mold assembly on the corresponding side to achieve molding 3D forming of the flat wire.

[0005] Furthermore, the lower mold assembly includes an outer guide block, an inner guide block, and a wire support groove block disposed on the lower mold base plate; a die slot for accommodating the lower mold cutter is formed between the outer guide block and the inner guide block; a wire support groove block is disposed at the feeding end in front of the outer guide block and the inner guide block for supporting and guiding the wire legs of the flat wire to be processed; multiple sets of the lower mold assemblies are connected to the lower mold mounting plate through corresponding lower mold mounting brackets.

[0006] Furthermore, the upper mold assembly includes an upper mold base plate, an upper mold cutter, and an upper mold limiting guide pin assembly; an upper cutter groove and multiple guide limiting holes are formed on the upper mold base plate, the upper mold cutter is fixedly embedded in the upper cutter groove, the upper mold limiting guide pin assembly is inserted into the guide limiting hole, and the bottom end of the pin of the upper mold limiting guide pin assembly is embedded in the corresponding guide hole of the lower mold assembly; multiple sets of the upper mold assemblies are connected to the upper mold mounting plate through corresponding upper mold mounting brackets.

[0007] Furthermore, the flat wire 3D forming device also includes a 2D flat wire feeding mechanism and a 3D flat wire receiving mechanism arranged along the material conveying direction. The 2D flat wire feeding mechanism clamps the 2D flat wire with one leg for feeding, and the 3D flat wire receiving mechanism is used to clamp and receive the 3D flat wire processed from the molding tower forming mechanism with both legs.

[0008] Furthermore, the flat wire 3D forming device also includes a module gauge for periodically calibrating 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 inspection mechanism, a carbon brush inspection mechanism, and a feeding and receiving mechanism.

[0010] Compared with the prior art, the beneficial effects of the present invention are as follows: The present application can perform 3D molding on 2D flat wires of different models and specifications in batches through the molding tower forming mechanism. The switching speed between different models of molds is fast, which meets the requirements of efficient 3D molding. In addition, with the 2D flat wire feeding mechanism and the 3D flat wire receiving mechanism, intelligent mass production is realized, with high production efficiency and pass rate, which is convenient for promotion and application in the field of flat wire motors involved in automotive intelligent manufacturing. Attached Figure Description

[0011] Figure 1 Examples of different flat lines formed from straight lines through 2D and 3D molding;

[0012] Figure 2 This is a schematic diagram of the molding tower forming mechanism;

[0013] Figure 3 This is an exploded view of the lower mold assembly and the upper mold assembly;

[0014] Figure 4 A schematic diagram of the lower die cutter and the upper die cutter;

[0015] Figure 5 This is a schematic diagram of a flat wire 3D forming device.

[0016] In the picture,

[0017] 100. Molding tower forming mechanism;

[0018] 110. Lower mold assembly; 111. Lower mold mounting bracket; 112. Lower mold base plate; 113. Lower mold outer guide block; 114. Lower mold inner guide block; 115. Wire leg support block; 116. Lower mold cutter; 117. Mold cutter floating assembly; 118. Lower mold guide block; 119. Material support block; 120. Upper mold assembly; 121. Upper mold mounting bracket; 122. Upper mold base plate; 123. Upper mold cutter; 124. Upper mold limiting guide pin assembly; 130. Lower mold mounting plate; 140. Upper mold mounting plate; 150. Molding drive assembly; 160. Sliding mounting plate; 170. Lifting and switching assembly; 180. Fixed back plate frame;

[0019] 200, 2D flat wire feeding mechanism;

[0020] 300, 3D flat wire receiving mechanism;

[0021] 400. Conveyor line;

[0022] 500, Module Inspection Tool. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] Flat wire 3D forming device

[0025] A flat wire 3D forming device includes a molding tower forming mechanism 100, which includes multiple lower mold assemblies 110 of different models mounted on a lower mold mounting plate 130, multiple 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 switching assembly 170, and a fixed back plate frame 180.

[0026] Molding principle: The lifting and switching component 170 drives the sliding mounting plate 160 to lift and lower as a whole to realize the switching of different mold types at the processing position. The molding drive component 150 drives the lower mold component 110 and the upper mold component 120 on the corresponding side to realize the 3D molding of flat lines.

[0027] The lower mold assembly 110 includes an outer guide block 113, an inner guide block 114, and a wire support groove block 115 disposed on the lower mold base plate 112. A die slot for accommodating a lower die cutter 116 is formed between the outer guide block 113 and the inner guide block 114. A wire support groove block 115 is disposed at the feeding end in front of the outer guide block 113 and the inner guide block 114 for supporting and guiding the wire legs of the flat wire to be processed. Multiple sets of the lower mold assemblies 110 are connected to the lower mold mounting plate 130 through corresponding lower mold mounting brackets 111.

[0028] Specifically, the lower plate surface of the lower mold base plate 112 is connected to the top surface of the transition horizontal plate of the lower mold mounting bracket 111, and the back of the transition vertical plate of the lower mold mounting bracket 111 is installed on the front plate surface of the lower mold mounting plate 130.

[0029] 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.

[0030] The die-cutting floating assembly 117 includes a floating block and a floating spring. The upper part of the floating block is slotted and fits into the lower part of the lower die-cutting 116.

[0031] Furthermore, a guide hole is provided on the guide block 114 inside the lower mold, and a guide slot is provided on the leg support block 115. A set of lower mold guide blocks 118 are installed into the guide slot of the leg support block 115.

[0032] Furthermore, two material support blocks 119 are provided on the front wall of the wire leg support block 115 for pre-support and guidance of the flat wire incoming material. The groove shape of the two material support blocks 119 is the same as the shape of the two grooves opened on the wire leg support block 115.

[0033] The upper mold assembly 120 includes an upper mold base plate 122, an upper mold cutter 123, and an upper mold limiting guide pin assembly 124. An upper cutter groove and multiple guide limiting holes are formed on the upper mold base plate 122. The upper mold cutter 123 is fixedly embedded in the upper cutter groove, and the upper mold limiting guide pin assembly 124 is inserted into the guide limiting hole. The bottom end of the pin of the upper mold limiting guide pin assembly 124 is embedded in the corresponding guide hole of the lower mold assembly 110. Multiple sets of the upper mold assemblies 120 are connected to the upper mold mounting plate 140 through corresponding upper mold mounting brackets 121.

[0034] Specifically, the upper plate surface of the upper mold base plate 122 is connected to the bottom surface of the transition horizontal plate of the upper mold mounting bracket 121, and the back of the transition vertical plate of the upper mold mounting bracket 121 is installed on the front plate surface of the upper mold mounting plate 140.

[0035] Specifically, guide holes are provided on both the online leg support block 115 and the lower mold guide block 118 to accommodate the lower section of the pin of the upper mold limiting guide pin assembly 124.

[0036] The upper die cutter 123 and the lower die cutter 116 match their cutting edges, and through extrusion, the middle part of the 2D flat line between them is formed to obtain a shape such as... Figure 1 The rightmost illustration shows a 3D head tilt.

[0037] The two molding drive assemblies 150 and the lifting switching assembly 170 may be in the form of a motor screw mechanism, a cylinder sliding mechanism or a linear motor drive.

[0038] This application preferentially employs a motor or cylinder screw mechanism. The screw nut is connected to the lifting and lowering mounting plate, but other methods can also be used.

[0039] Further, see Figure 5 The flat wire 3D forming device also includes a 2D flat wire feeding mechanism 200 and a 3D flat wire receiving mechanism 300 arranged along the material conveying direction. The 2D flat wire feeding mechanism 200 clamps the 2D flat wire on one leg for feeding, and the 3D flat wire receiving mechanism 300 is used to clamp and receive the 3D flat wire processed from the molding tower forming mechanism 100 on both legs.

[0040] In a specific example, the 2D flat wire feeding mechanism 200 and the 3D flat wire receiving mechanism 300 share a single conveyor line 400. Preferably, a set of linear motors is used, with the two mounted on different motor actuators.

[0041] Further, see Figure 5 The flat wire 3D forming device also includes a module gauge 500 for periodically calibrating the molding accuracy.

[0042] Stator wire forming system

[0043] A stator wire forming system (not shown in the figure) includes a flat wire feeding module, a wire cutting module, a flat wire 2D forming device, a flat wire 3D forming device according to the above, a wire type optical inspection mechanism, a carbon brush inspection mechanism, and a feeding and receiving mechanism.

[0044] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to 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 forming device includes a molding tower forming mechanism (100), which includes multiple lower mold assemblies (110) of different models installed on the lower mold mounting plate (130), multiple upper mold assemblies (120) of different models installed on the upper mold mounting plate (140), a molding drive assembly (150), a sliding mounting plate (160), a lifting switching assembly (170), and a fixed back plate frame (180). The lower mold assembly (110) includes an outer guide block (113), an inner guide block (114), and a wire support block (115) disposed on the lower mold base plate (112); a die slot for accommodating a lower die cutter (116) is formed between the outer guide block (113) and the inner guide block (114); a wire support block (115) is disposed at the feed end in front of the outer guide block (113) and the inner guide block (114) for supporting and guiding the wire legs of the flat wire to be processed; The upper mold assembly (120) includes an upper mold base plate (122), an upper mold cutter (123), and an upper mold limiting guide pin assembly (124); an upper cutter groove and multiple guide limiting holes are provided on the upper mold base plate (122), and the upper mold cutter (123) is fixedly embedded in the upper cutter groove; The lifting and switching component (170) drives the sliding mounting plate (160) to lift and lower as a whole to realize the switching of different mold types at the processing position. The molding drive component (150) drives the lower mold component (110) and upper mold component (120) on the corresponding side to realize the molding 3D forming of flat lines.

2. The flat wire 3D forming device according to claim 1, characterized in that: Multiple sets of the lower mold assemblies (110) are connected to the lower mold mounting plate (130) via corresponding lower mold mounting brackets (111).

3. The flat wire 3D forming apparatus 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) through 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 limiting guide pin assembly (124) is inserted into the guide limiting hole, and the bottom end of the pin of the upper mold limiting guide pin assembly (124) is embedded in the corresponding guide hole of the lower mold assembly (110); multiple sets of the upper mold assemblies (120) are connected to the upper mold mounting plate (140) through the corresponding upper mold mounting bracket (121).

5. The flat wire 3D forming apparatus according to claim 2, characterized in that: The two molding drive assemblies (150) and one lifting switching assembly (170) may be in the form of a motor screw mechanism, a cylinder sliding mechanism or a linear motor drive.

6. The flat wire 3D forming apparatus according to claim 1, characterized in that: The flat wire 3D forming device also includes a 2D flat wire feeding mechanism (200) and a 3D flat wire receiving mechanism (300) arranged along the material conveying direction. The 2D flat wire feeding mechanism (200) clamps the 2D flat wire for single-leg feeding, and the 3D flat wire receiving mechanism (300) is used for double-leg clamping to receive the 3D flat wire processed from the molding tower forming mechanism (100).

7. The flat wire 3D forming apparatus according to claim 1, characterized in that: The flat wire 3D forming device also includes a module gauge (500) for periodically calibrating the 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 wire optical inspection mechanism, a carbon brush inspection mechanism, and a feeding and receiving mechanism.

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