Intelligent forming system for stator flat wire

Abstract

The invention provides an intelligent stator flat wire forming system, which belongs to the field of intelligent automobile manufacturing and comprises an unwinding buffer module, a straightening module, a variable-length wire feeding module, a depainting self-detection module, a wire cutting module, a 2D forming module, a 3D forming module, a carrying module and a discharging module. The flat wire feeding visual detection module is used for detecting the line type of the flat wire before paint removal; the variable-length wire feeding module is used for supplying flat wires with different lengths according to setting; the depainting self-detection module is provided with an optical detection module and is used for detecting whether depainting is complete or not; the forming visual detection module is used for detecting whether the shape of the crown end of the flat wire after 3D compression molding reaches the standard or not; and the carbon brush detection module detects the insulativity of the 3D flat wire. According to the system, the feeding appearance, the line type after forming, the size and damage are detected in real time, integrated comprehensive machining of flat wires of different lengths and line types of different specifications can be provided on the same system, the intelligent degree is high, and application and popularization in the field of automobile manufacturing are facilitated.

Description

Technical Field

[0001] The invention belongs to the field of intelligent manufacturing of automobiles, and particularly relates to an intelligent forming system for stator flat wires. 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 endurance mileage of the whole vehicle. In recent years, due to its high power density, high efficiency, low noise, and good heat dissipation performance, the flat wire motor has gradually become the first choice for new energy vehicle drive motors. However, in the manufacturing process of flat wire motors, the insertion of stator wires, pins, I-pins, Hair-pins, and X-pins, which are collectively referred to as stator wires in this application, how to produce and manufacture them efficiently and without damage is a technical problem. The traditional manufacturing methods of manual wire feeding, wire cutting, and forming have problems such as low production efficiency, difficult to guarantee the qualification rate of stators, easy scratching of flat wires, and cannot detect the forming quality of flat wires in real time, which not only increases the manufacturing cost but also affects the performance and reliability of the motor. Therefore, developing an efficient and precise intelligent forming system for stator 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 an intelligent forming system for stator flat wires, which can solve the above problems.

[0004] The intelligent forming system for stator flat wires includes a unwind buffer module, a straightening module, a variable-length wire feeding module, a de-painting and self-detection module, a wire cutting module, a 2D forming module, a 3D forming module, a handling module, and a blanking module arranged in sequence; a flat wire feeding vision detection module is arranged downstream of the straightening module for detecting the wire type of the flat wire before de-painting; the variable-length wire feeding module is used to supply straightening flat wires of different lengths according to the setting; the de-painting and self-detection module is equipped with an optical detection module for detecting whether the de-painting is complete and whether the surface of the bare copper of the flat wire after de-painting is clean and dust-free; a forming vision detection module is arranged downstream of the 3D forming module for detecting whether the crown end shape of the flat wire after 3D molding is up to standard; a carbon brush detection module is arranged in the forming vision detection module for detecting the insulation of the 3D flat wire.

[0005] Further, the unwind buffer module includes two sets of coil mechanisms, two material detection mechanisms, a wire drawing and guiding mechanism, and a wire feeding weight buffer mechanism; the two sets of coil mechanisms continuously supply materials with seamless switching when there is no material, the material detection mechanism detects the remaining state of the flat wire of the corresponding coil mechanism, and the wire drawing and guiding mechanism receives the flat wire supplied by the coil mechanism and guides it; the wire feeding weight buffer mechanism includes a pre-correction component, a constant tension load-bearing buffer wheel group, and a balance cylinder for ensuring the wire feeding tension.

[0006] Further, the straightening module includes multiple groups of horizontally aligning mechanisms and vertically shaping mechanisms arranged alternately.

[0007] Further, the flat wire feeding vision detection module includes a flat wire feeding camera and a flat wire feeding detection light source arranged on the vision detection frame.

[0008] Further, the variable-length wire feeding module includes a calibration frame, a lower coding base, a coding wheel drive assembly, a lower coding wheel, an upper coding wheel, an upper coding base, and a pressing drive assembly; the lower coding base is installed on the calibration frame; the lower coding wheel is installed on the lower coding base and is driven to rotate and feed by the coding wheel drive assembly; the upper coding wheel is installed on the upper coding base, and the upper coding base is driven to move up and down by the pressing drive assembly, so as to convey the flat wire according to a set length.

[0009] Further, the paint removal self-detection module includes a three-link drive mechanism, two guiding wire support modules, a multi-head paint removal module arranged on the peeling frame, and a paint ash absorption module; the two guiding wire support modules are arranged on the front and rear sides of the peeling frame, and both are installed on the sliding top plate of the three-link drive mechanism at the bottom; the multi-head paint removal module includes multiple groups of paint removal heads, a paint removal adjustment component, a paint removal detection camera, and a paint removal adapter seat; the paint removal heads are installed on the paint removal adjustment component, the paint removal detection camera is installed on the paint removal heads, and the entire multi-head paint removal module is installed on the peeling frame through the paint removal adapter seat.

[0010] Further, the wire cutting module includes a wire cutting mechanism, a receiving pipe, a receiving box, a wire cutting controller, and a wire cutting bench; the wire cutting mechanism is arranged on the top plate of the wire cutting bench, the top end of the receiving pipe is arranged at the receiving port on the top plate of the wire cutting bench, the lower end of the receiving pipe is arranged opposite to the receiving box on the bottom plate of the wire cutting bench below, and the wire cutting controller controls the wire cutting action of the wire cutting mechanism.

[0011] Further, the 2D forming module includes a 2D bending total support plate, a bending reference plate, a bending disc provided with a bending wheel shaft, and a bending wire inlet component; the bending reference plate with a bending opening in the middle is buckled above the 2D bending total support plate, and the bending disc is driven to rotate and lift along the bending opening; the bending wheel shaft is vertically arranged eccentrically on the top surface of the bending disc, and the bending wire inlet component horizontally conveys the flat wire above the middle of the bending opening of the bending reference plate.

[0012] Further, the 3D forming module adopts a die pressing tower forming mechanism. The 3D forming module includes multiple different types of lower die components installed on the lower die mounting plate, multiple different types of upper die components installed on the upper die mounting plate, a die pressing drive assembly, a sliding mounting plate, a lifting and switching component, and a fixed backplane frame; the lifting and switching component drives the overall lifting of the sliding mounting plate to realize the switching of different types of dies at the processing position, and the die pressing drive assembly drives the corresponding lower die component and upper die component on the side to realize the die pressing 3D forming of the flat wire.

[0013] Further, the forming vision detection module includes a forming vision detection frame, a forming detection camera, and a forming detection backlight, which are used to check whether the overall dimensions and wire shapes of the flat wire after 3D forming meet the standards.

[0014] Further, the carbon brush detection module includes a carbon brush detector arranged on the insulation detection frame.

[0015] Further, the handling module includes a 2D longitudinal handling module, a 2D flat wire clamping and rotating mechanism, a 3D longitudinal handling module, a 2D flat wire single-leg clamping mechanism, a 3D flat wire double-leg clamping mechanism, a 3D detection clamping mechanism, a 3D temporary storage clamping mechanism, a 3D blanking longitudinal handling module, and a 3D wire clamping and rotating mechanism; the 2D flat wire clamping and rotating mechanism moves longitudinally along the 2D longitudinal handling module and rotates to change the direction, transferring the 2D flat wire to the 2D flat wire single-leg clamping mechanism; the 2D flat wire single-leg clamping mechanism, the 3D flat wire double-leg clamping mechanism, and the 3D detection clamping mechanism move longitudinally along the 3D longitudinal handling module. The 3D flat wire double-leg clamping mechanism receives the 3D flat wire processed by the 3D forming module, longitudinally transfers it to the 3D temporary storage clamping mechanism for temporary storage or to the forming vision detection module for wire shape and size detection. The 3D detection clamping mechanism receives the detected 3D flat wire and longitudinally transfers it to the 3D wire clamping and rotating mechanism, and the 3D wire clamping and rotating mechanism moves the 3D flat wire to the end and blanks it at the blanking module.

[0016] Further, the blanking module includes a blanking table frame, a sliding rod wire frame, and a sliding material frame. After the 3D flat wire is detected, it is moved into the sliding rod wire frame or the sliding material frame through the handling module.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: The stator flat wire intelligent forming system of the present application can detect the appearance of the loaded material, the wire shape, size, and damage after forming in real time, and can provide integrated comprehensive processing of flat wires with different lengths and different specifications of wire shapes on the same system, with a high degree of intelligence, which is convenient for popularization and application in the field of automobile manufacturing. Description of the Drawings

[0018] Figure 1 and Figure 2 are schematic diagrams of different perspectives of the stator flat wire intelligent forming system of the present invention; Figure 3 is a schematic diagram of the wire feeding weight buffer mechanism; Figure 4 is a schematic diagram of the variable-length wire feeding module; Figure 5 is a schematic diagram of the paint removal self-detection module; Figure 6 is a schematic diagram of the wire cutting module; Figure 7 is a schematic diagram of the 2D forming module; Figure 8 Schematic diagram of the 3D forming module; Figure 9 Schematic diagram of the forming vision inspection module; Figure 10 Partial structural schematic diagram of the carbon brush inspection module; Figure 11 Schematic diagram of the handling module; Figure 12 Schematic diagram of the blanking module.

[0019] In the figure, 10. Unwinding buffer module; 11. Coil mechanism; 12. Material detection mechanism; 13. Wire drawing guiding mechanism; 14. Wire feeding weight buffer mechanism; 141. Pre-correction component; 142. Constant tension load-bearing buffer wheel set; 143. Balance cylinder; 144. Weight height measurement component; 20. Straightening module; 21. Horizontal wire aligning mechanism; 22. Vertical shaping mechanism; 30. Flat wire feeding vision inspection module; 40. Variable length wire feeding module; 41. Calibration frame; 42. Lower coding seat; 43. Coding wheel drive component; 44. Lower coding wheel; 45. Upper coding wheel; 46. Upper coding seat; 47. Lower pressing drive component; 48. Alignment guiding seat; 50. De-painting self-inspection module; 51. Three-link drive mechanism; 52. Guiding wire support module; 53. Peeling frame; 54. Multi-head de-painting module; 541. De-painting head; 542. De-painting adjustment component; 543. De-painting inspection camera; 55. Paint ash absorption module; 60. Wire cutting module; 61. Wire cutting mechanism; 62. Material receiving pipe; 63. Material receiving box; 64. Wire cutting controller; 65. Wire cutting table frame; 66. Wire cutting feeding mechanism; 70. 2D forming module; 71. 2D bending total support plate; 72. Bending reference plate; 74. Bending wheel shaft; 73. Bending disc; 75. Bending wire inlet component; 76. Bending support plate; 77. Rotation drive component; 78. Lifting drive component; 79. Floating support frame; 80. 3D forming module; 83. Lower die mounting plate; 81. Lower die component; 84. Upper die mounting plate; 82. Upper die component; 85. Die pressing drive component; 86. Sliding mounting plate; 87. Lifting switching component; 88. Fixed back plate frame; 90. Forming vision inspection module; 91. Forming vision inspection frame; 92. Forming inspection camera; 93. Forming inspection backlight; 100. Carbon brush inspection module; 102. Insulation inspection frame; 101. Carbon brush detector; 103. Carbon brush tester body; 110. Handling module; 111. 2D longitudinal handling module; 112. 2D flat wire clamping and rotating mechanism; 113. 3D longitudinal handling module; 114. 2D flat wire single-leg clamping mechanism; 115. 3D flat wire double-leg clamping mechanism; 116. 3D detection and clamping mechanism; 117. 3D temporary storage and clamping mechanism; 118. 3D blanking longitudinal handling module; 119. 3D wire clamping and rotating mechanism; 120. Blanking module; 121. Blanking bench; 122. Slide rod wire rack; 123. Sliding material box. Detailed implementation manners

[0020] 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. Obviously, 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.

[0021] It should be understood that the "system", "device", "unit" and / or "module" used in this specification is a method for distinguishing different components, elements, parts, portions or assemblies at different levels. However, if other words can achieve the same purpose, the said words can be replaced by other expressions.

[0022] A stator flat wire intelligent forming system, see Figures 1 - 12 , the system includes a winding buffer module 10, a straightening module 20, a variable-length wire feeding module 40, a paint-removing self-detection module 50, a wire cutting module 60, a 2D forming module 70, a 3D forming module 80, a handling module 110 and a blanking module 120 arranged in sequence.

[0023] A flat wire feeding vision detection module 30 is provided downstream of the straightening module 20 for detecting the flat wire line type before paint removal; the variable-length wire feeding module 40 is used to supply straightening flat wires of different lengths according to the setting; the paint-removing self-detection module 50 is equipped with an optical detection module for detecting whether the paint removal is perfect and whether the surface of the bare copper of the flat wire after paint removal is clean and dust-free; a forming vision detection module 90 is provided downstream of the 3D forming module 80 for detecting whether the shape of the crown end of the flat wire after 3D die pressing forming meets the standard; a carbon brush detection module 100 is provided in the forming vision detection module 90 for detecting the insulation of the 3D flat wire.

[0024] Among them, see Figure 1 and Figure 3, the unwind buffer module 10 includes two sets of coil mechanisms 11, two material detection mechanisms 12, a wire extraction guiding mechanism 13, and a wire feeding counterweight buffer mechanism 14; the two sets of coil mechanisms 11 continuously supply materials without material switching connection, the material detection mechanism 12 detects the remaining state of the flat wire of the corresponding coil mechanism 11, and the wire extraction guiding mechanism 13 receives the flat wire supplied from the coil mechanism 11 and guides it; the wire feeding counterweight buffer mechanism 14 includes a pre-calibration component 141, a constant tension load-bearing buffer wheel set 142, and a balance cylinder 143, which are used to ensure the wire feeding tension.

[0025] Furthermore, the wire feeding counterweight buffer mechanism 14 further includes a counterweight height measurement component 144, which is used to measure the lifting height of the counterweight wheel set to facilitate the control of the flat wire conveying tension.

[0026] Among them, the straightening module 20 includes multiple groups of horizontally arranged wire aligning mechanisms 21 and vertically arranged shaping mechanisms 22 that are alternately arranged.

[0027] The horizontally arranged wire aligning mechanism 21 and the vertically arranged shaping mechanism 22 adopt the form of multiple groups of shaping wheels or a combination of shaping wheels and differential heads. The differential head is used to adjust the clamping distance between the relative shaping wheel parts and is adjustable to fit flat wires of different specifications.

[0028] Among them, the flat wire loading vision detection module 30 includes a flat wire loading camera and a flat wire loading detection light source arranged on the vision detection frame.

[0029] Among them, see Figure 4 , the variable-length wire feeding module 40, the variable-length wire feeding module 40 includes a calibration frame 41, a lower coding base 42, a coding wheel drive assembly 43, a lower coding wheel 44, an upper coding wheel 45, an upper coding base 46, and a lower pressing drive assembly 47; the lower coding base 42 is installed on the calibration frame 41; the lower coding wheel 44 is installed on the lower coding base 44 and is driven to rotate and feed by the coding wheel drive assembly 43; the upper coding wheel 45 is installed on the upper coding base 46, and the upper coding base 46 is driven to move up and down by the lower pressing drive assembly 47, so as to convey the flat wire according to the set length.

[0030] Furthermore, the variable-length wire feeding module 40 further includes an alignment guiding seat 48.

[0031] Among them, see Figure 5, the paint-removing self-inspection module 50 includes a three-link drive mechanism 51, two guide wire support modules 52, a multi-head paint-removing module 54 arranged on the peeling frame 53, and a paint and ash suction module 55; the two guide wire support modules 52 are arranged on the front and rear sides of the peeling frame 53, and are both installed on the sliding top plate of the three-link drive mechanism 51 at the bottom; the multi-head paint-removing module 54 includes multiple groups of paint-removing heads 541, a paint-removing adjustment component 542, a paint-removing detection camera 543, and a paint-removing adapter; the paint-removing heads 541 are installed on the paint-removing adjustment component 542, the paint-removing detection camera 543 is installed on the paint-removing head 541, and the entire multi-head paint-removing module 54 is installed on the peeling frame 53 through the paint-removing adapter.

[0032] The three-link drive mechanism 51 includes a linkage driver, a wire-dragging sliding base for connecting the upper part to the guide wire support module, a peeling sliding base for connecting the upper part to the peeling frame, and a variable-spacing link group; the wire-dragging sliding base and the peeling sliding base are slidably arranged at both ends of the bottom on the variable-spacing linkage rail module, both ends of the variable-spacing link group are fixed and connected to the wire-dragging sliding base and the peeling sliding base in the middle through a linkage column, the bottom of the peeling sliding base is also connected to the driving moving end of the linkage driver, and when the linkage driver drives, it linkage-adjusts the distance between the two guide wire support modules 52 and the peeling frame 53.

[0033] The paint and ash suction module 55 includes a processing shield, multiple dust suction branch pipes, a dust suction main pipe, and an external dust collector and a suction fan. A wire passing hole is opened in the middle of the processing shield, and a processing window is opened on the side. Multiple dust suction branch pipes are connected to the processing shield in a cross manner with the processing direction of the multi-head paint-removing module 54. The multiple dust suction branch pipes are aggregated through the dust suction main pipe at the top of the peeling frame 53 and then connected to the external dust collector.

[0034] The paint-removing self-inspection module 50 further includes a wire guiding and cleaning module. The wire guiding and cleaning module includes a guide groove block installed on a guide installation bottom plate, two groups of correction wheel groups arranged vertically front and back, and a brush chamber; the flattened wire after peeling passes through the correction wheel groups and then passes through the brush chamber for cleaning the surface of the copper wire.

[0035] Among them, referring to Figure 6 , the wire cutting module 60 includes a wire cutting mechanism 61, a receiving pipe 62, a receiving box 63, a wire cutting controller 64, and a wire cutting bench 65; the wire cutting mechanism 61 is arranged on the top plate of the wire cutting bench 65, the top end of the receiving pipe 62 is arranged at the receiving port on the top plate of the wire cutting bench 65, the lower end of the receiving pipe 62 is arranged facing the receiving box 63 on the bottom plate of the wire cutting bench 65 below, and the wire cutting controller 64 controls the wire cutting action of the wire cutting mechanism 61.

[0036] The tangent mechanism 61 includes a tangent driver, a tangent gearbox, a slide plate assembly, an upper cutter assembly, a lower cutter assembly, a wire guiding assembly, and a blanking sensor; the upper cutter assembly and the lower cutter assembly are respectively mounted to the output side of the tangent gearbox through corresponding slide plate assemblies, the tangent driver drives the upper cutter assembly to reciprocate towards the lower cutter assembly through the tangent gearbox, the wire guiding assembly horizontally penetrates through the middle of the tangent gearbox, and the blanking sensor is arranged at the upper cutter assembly to monitor the material cutting state.

[0037] The tangent mechanism 61 further includes a blanking upper pipe, a blanking hole is formed in the lower cutter assembly, and the upper end of the blanking upper pipe is connected to the blanking hole.

[0038] An upstream of the tangent module 60 is further provided with a tangent feeding mechanism 66, and the tangent feeding mechanism 66 uses a circulating slide rail conveying method for circulating feeding.

[0039] Among them, referring to Figure 7 , the 2D forming module 70 includes a 2D bending total support plate 71, a bending reference plate 72, a bending disc 73 provided with a bending wheel shaft 74, and a bending wire inlet assembly 75; the bending reference plate 72 with a bending opening in the middle is buckled above the 2D bending total support plate 71, and the bending disc 73 is driven to rotate and lift along the bending opening; the bending wheel shaft 74 is vertically arranged eccentrically on the top surface of the bending disc 73, and the bending wire inlet assembly 75 horizontally conveys flat wires towards the middle above the bending opening of the bending reference plate 72.

[0040] The 2D forming module 70 further includes a bending support plate 76, the bending support plate 76 is arranged above the bending reference plate 72, and the bending support plate 76 is provided with the same bending opening as the bending reference plate 72.

[0041] The 2D forming module 70 further includes a rotation driving assembly 77 for driving the rotation of the bending disc 73.

[0042] The 2D forming module 70 further includes a lifting driving assembly 78 and a floating support frame 79. The top of the lifting rod end of the lifting driving assembly 78 is fixedly connected to the bottom of the bottom plate of the floating support frame 79, the top plate of the floating support frame 79 is fixedly connected to the rotation driving assembly 77, and the lifting of the lifting rod driven by the lifting driving assembly 78 drives the synchronous lifting of the rotation driving assembly 77, the floating support frame 79, and the bending disc 73.

[0043] Among them, referring to Figure 8, the 3D forming module 80 adopts a molding tower forming mechanism. The 3D forming module 80 includes a plurality of lower die components 81 of different models installed on the lower die mounting plate 83, a plurality of upper die components 82 of different models installed on the upper die mounting plate 84, a molding drive component 85, a sliding mounting plate 86, a lifting and switching component 87, and a fixed backplane frame 88. The lifting and switching component 87 drives the overall lifting of the sliding mounting plate 86 to realize the switching of different models of dies at the processing position, and the molding drive component 85 drives the corresponding lower die component 81 and upper die component 82 on one side to realize the 3D molding of the flat wire by molding.

[0044] Among them, referring to Figure 9 , the forming vision inspection module 90 includes a forming vision inspection frame 91, a forming inspection camera 92, and a forming inspection backlight 93, and is used to check whether the overall dimensions and wire shapes of the flat wire after 3D forming meet the standards.

[0045] Among them, referring to Figure 10 , the carbon brush inspection module 100 includes a carbon brush detector 101 arranged on the insulation inspection frame 102.

[0046] Of course, the illustrated carbon brush tester 101 is the carbon brush electrode of the tester, and there is also the carbon brush tester body 103. Refer to the attached drawings.

[0047] Among them, referring to Figure 11 , the handling module 110 includes a 2D longitudinal handling module 111, a 2D flat wire clamping and rotating mechanism 112, a 3D longitudinal handling module 113, a 2D flat wire single-leg clamping mechanism 114, a 3D flat wire double-leg clamping mechanism 115, a 3D inspection clamping mechanism 116, a 3D temporary storage clamping mechanism 117, a 3D blanking longitudinal handling module 118, and a 3D wire clamping and rotating mechanism 119. The 2D flat wire clamping and rotating mechanism 112 moves longitudinally along the 2D longitudinal handling module 111 and rotates and changes direction to transfer the 2D flat wire to the 2D flat wire single-leg clamping mechanism 114.

[0048] The 2D flat wire single-leg clamping mechanism 114, the 3D flat wire double-leg clamping mechanism 115, and the 3D inspection clamping mechanism 116 move longitudinally along the 3D longitudinal handling module 113. The 3D flat wire double-leg clamping mechanism 115 receives the 3D flat wire processed by the 3D forming module 80, longitudinally transfers it to the 3D temporary storage clamping mechanism 117 for temporary storage or to the forming vision inspection module 90 for wire shape and dimension inspection. The 3D inspection clamping mechanism 116 receives the inspected 3D flat wire and longitudinally transfers it to the 3D wire clamping and rotating mechanism 119. The 3D wire clamping and rotating mechanism 119 moves the 3D flat wire to the end and blanks it at the blanking module 120.

[0049] Among them, referring to Figure 12, the blanking module 120 includes a blanking bench 121, a slide rod wire rack 122, and a sliding material frame 123. After the 3D flat wire is detected, it is moved into the slide rod wire rack 122 or the sliding material frame 123 through the handling module 110.

[0050] This system can be promoted in the field of intelligent manufacturing of flat wire motors for intelligent and automated unmanned wire forming manufacturing.

[0051] 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 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. The stator flat wire intelligent forming system includes a unwind buffer module (10), a straightening module (20), a variable length wire feeding module (40), a paint removing and self-detection module (50), a cutting module (60), a 2D forming module (70), a 3D forming module (80), a handling module (110) and a blanking module (120) arranged in sequence; characterized in that: A flat wire feeding vision inspection module (30) is provided downstream of the straightening module (20) for detecting the shape of the flat wire before de-painting; a variable-length wire feeding module (40) is used to supply straightening flat wires of different lengths according to the setting; the de-painting self-inspection module (50) is equipped with an optical inspection module itself for detecting whether the de-painting is perfect and whether the surface of the bare copper of the flat wire after de-painting is clean and dust-free. A forming vision inspection module (90) is provided downstream of the 3D forming module (80) for detecting whether the shape of the crown end of the flat wire after 3D molding is up to standard; a carbon brush inspection module (100) is provided in the forming vision inspection module (90) for detecting the insulation of the 3D flat wire.

2. The stator flat wire intelligent forming system according to claim 1, characterized in that: The unwind buffer module (10) includes two sets of coil mechanisms (11), two material detection mechanisms (12), a wire drawing guiding mechanism (13) and a wire feeding counterweight buffer mechanism (14); the two sets of coil mechanisms (11) continuously supply materials with seamless switching when there is no material, the material detection mechanism (12) detects the remaining state of the flat wire of the corresponding coil mechanism (11), and the wire drawing guiding mechanism (13) receives the flat wire supplied from the coil mechanism (11) and guides it; the wire feeding counterweight buffer mechanism (14) includes a pre-correction component (141), a constant-tension load-bearing buffer wheel set (142) and a balance cylinder (143) for ensuring the wire feeding tension.

3. The stator flat wire intelligent forming system according to claim 1, wherein: The straightening module (20) includes multiple sets of horizontally arranged wire straightening mechanisms (21) and vertically arranged wire shaping mechanisms (22) which are arranged alternately.

4. The stator flat wire intelligent forming system according to claim 1, characterized in that: The flat wire feeding vision inspection module (30) includes a flat wire feeding camera and a flat wire feeding detection light source arranged on the vision inspection frame.

5. The stator flat wire intelligent forming system according to claim 1, wherein: The variable-length wire feeding module (40) includes a calibration frame (41), a lower encoder base (42), an encoder wheel drive assembly (43), a lower encoder wheel (44), an upper encoder wheel (45), an upper encoder base (46) and a lower pressing drive assembly (47); the lower encoder base (42) is installed on the calibration frame (41); the lower encoder wheel (44) is installed on the lower encoder base (44) and is driven to rotate and feed through the encoder wheel drive assembly (43); the upper encoder wheel (45) is installed on the upper encoder base (46), and the upper encoder base (46) is driven to move up and down through the lower pressing drive assembly (47), so as to convey the flat wire according to the set length.

6. The stator flat wire intelligent forming system according to claim 1, characterized in that: The de-painting self-inspection module (50) includes a three-link drive mechanism (51), two guiding wire support modules (52), a multi-head de-painting module (54) arranged on the de-skinning frame (53) and a paint ash suction module (55); the two guiding wire support modules (52) are arranged on the front and rear sides of the de-skinning frame (53), and are both installed on the sliding top plate of the three-link drive mechanism (51) at the bottom; the multi-head de-painting module (54) includes multiple sets of de-painting heads (541), de-painting adjustment components (542), de-painting detection cameras (543) and de-painting adapters; the de-painting heads (541) are installed on the de-painting adjustment components (542), the de-painting detection cameras (543) are installed on the de-painting heads (541), and the entire multi-head de-painting module (54) is installed on the de-skinning frame (53) through the de-painting adapter.

7. The stator flat wire intelligent forming system according to claim 1, wherein: The tangent module (60) includes a tangent mechanism (61), a material receiving pipe (62), a material receiving box (63), a tangent controller (64) and a tangent bench (65); the tangent mechanism (61) is arranged on the top plate of the tangent bench (65), the top end of the material receiving pipe (62) is arranged at the material receiving port on the top plate of the tangent bench (65), the lower end of the material receiving pipe (62) is arranged opposite to the material receiving box (63) on the bottom plate of the tangent bench (65) below, and the tangent controller (64) controls the tangent action of the tangent mechanism (61).

8. The stator flat wire intelligent forming system according to claim 1, characterized in that: The 2D forming module (70) includes a 2D bending total support plate (71), a bending reference plate (72), a bending disc (73) provided with a bending wheel shaft (74) and a bending wire feeding assembly (75); the bending reference plate (72) with a bending opening in the middle is buckled above the 2D bending total support plate (71), and the bending disc (73) is driven to rotate and lift along the bending opening; the bending wheel shaft (74) is vertically arranged eccentrically on the top surface of the bending disc (73), and the bending wire feeding assembly (75) horizontally conveys a flat wire towards the middle above the bending opening of the bending reference plate (72).

9. The stator flat wire intelligent forming system according to claim 1, characterized in that: The 3D forming module (80) adopts a die pressing tower forming mechanism. The 3D forming module (80) includes a plurality of lower die components (81) of different models installed on a lower die mounting plate (83), a plurality of upper die components (82) of different models installed on an upper die mounting plate (84), a die pressing driving assembly (85), a sliding mounting plate (86), a lifting and switching assembly (87) and a fixed back plate frame (88); the lifting and switching assembly (87) drives the sliding mounting plate (86) to lift integrally to realize the switching of different models of dies at the processing position, and the die pressing driving assembly (85) drives the corresponding lower die component (81) and upper die component (82) on one side to realize the die pressing 3D forming of the flat wire.

10. The stator flat wire intelligent forming system according to claim 1, characterized in that: The forming vision inspection module (90) includes a forming vision inspection frame (91), a forming inspection camera (92) and a forming inspection backlight (93), and is used for inspecting whether the overall dimensions and wire types of the flat wire after 3D forming meet the standards.

11. The stator flat wire intelligent forming system according to claim 1, characterized in that: The carbon brush inspection module (100) includes a carbon brush detector (101) arranged on an insulation inspection frame (102).

12. The stator flat wire intelligent forming system according to claim 1, wherein: The handling module (110) includes a 2D longitudinal handling module (111), a 2D flat wire clamping and rotating mechanism (112), a 3D longitudinal handling module (113), a 2D flat wire single-leg clamping mechanism (114), a 3D flat wire double-leg clamping mechanism (115), a 3D inspection clamping mechanism (116), a 3D temporary storage clamping mechanism (117), a 3D blanking longitudinal handling module (118) and a 3D wire clamping and rotating mechanism (119); the 2D flat wire clamping and rotating mechanism (112) moves longitudinally and rotates and changes direction along the 2D longitudinal handling module (111), and transfers the 2D flat wire to the 2D flat wire single-leg clamping mechanism (114). The 2D flat wire single-leg clamping mechanism (114), 3D flat wire double-leg clamping mechanism (115), and 3D detection clamping mechanism (116) move longitudinally along the 3D longitudinal handling module (113). The 3D flat wire double-leg clamping mechanism (115) receives the 3D flat wire processed by the 3D forming module (80) and longitudinally transfers it to the 3D temporary storage clamping mechanism (117) for temporary storage or to the forming vision detection module (90) for wire type and dimension detection. The 3D detection clamping mechanism (116) receives the detected 3D flat wire and longitudinally transfers it to the 3D wire clamping rotation mechanism (119). The 3D wire clamping rotation mechanism (119) moves the 3D flat wire to the end and discharges it at the blanking module (120).

13. The stator flat wire intelligent forming system according to claim 1, wherein: The blanking module (120) includes a blanking bench (121), a slide rod wire rack (122), and a sliding material frame (123). After being detected, the 3D flat wire is moved into the slide rod wire rack (122) or the sliding material frame (123) through the handling module (110).

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