Intelligent forming and wire plugging system for stator flat wire

Abstract

The invention provides an intelligent forming and wire inserting system for stator flat wires, and belongs to the field of intelligent manufacturing of automobiles, and the system comprises a variable-pitch stepping feeding device which can provide corrected and visually detected flat wire raw materials in a controllable variable-length stepping manner; the depainting self-detection module adopts a multi-head laser to depeel the flat wire at a set position; the wire cutting module is used for cutting off the flat wire at the peeled part; the flat wire forming device is used for carrying out bending, compression molding, detection and screening on the flat wires; the manipulator wire plugging mechanism is matched with the rotating disc type single-layer wire plugging device to plug wires to form a single-layer whole-circle flat wire layer; and the split type wire plugging device is used for receiving a single-layer whole-circle flat wire layer and completing stator winding wiring on the assumed stator tray full-plugging layer. The molding tower forming mechanism is adopted, forming modules can be rapidly switched, layered wire plugging of split type wire plugging is matched with intelligent visual detection, the wire plugging quality and efficiency are guaranteed, and the device can be popularized and applied to the field of manufacturing of driving motors of new energy automobiles or manufacturing of other motors needing efficient and accurate wire plugging.

Description

Technical Field

[0001] The present invention belongs to the field of intelligent manufacturing of automobiles, and particularly relates to an intelligent forming and inserting wire system for stator flat wires. Background Art

[0002] 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.

[0003] 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 the drive motor of new energy vehicles. However, in the manufacturing process of the flat wire motor, the stator wire inserting link is a technical difficulty. The traditional manual wire inserting method has problems such as low production efficiency, difficult to guarantee the slot filling rate, and easy scratching of the enameled wire, which not only increases the manufacturing cost, but also affects the performance and reliability of the motor. Therefore, developing an efficient and precise automatic wire inserting system is of great significance for improving the manufacturing quality and production efficiency of flat wire motors. Summary of the Invention

[0004] In order to overcome the deficiencies of the prior art, the purpose of the present invention is to develop an intelligent forming and inserting wire system for the flat wire stator of the electric drive of new energy vehicles to solve the problem of stator wire inserting in the manufacturing process of flat wire motors.

[0005] An intelligent forming and inserting wire system for stator flat wires includes a variable pitch stepping feeding device, a paint removing self-detection module, a wire cutting module, a flat wire forming device, a manipulator wire inserting mechanism, a rotary single-layer wire inserting device, a split wire inserting device and a system controller arranged in sequence; the variable pitch stepping feeding device controllably and variably steps to provide the flat wire raw material after calibration and visual inspection, the paint removing self-detection module uses multi-head lasers to remove the paint at the set position of the flat wire, the wire cutting module cuts the flat wire at the paint removed position, the flat wire forming device bends and presses the cut flat wire into shape and detects and screens it, the manipulator wire inserting mechanism picks up the formed flat wire and inserts the wire at the rotary single-layer wire inserting device to form a single-layer complete circle flat wire layer, and the split wire inserting device receives the single-layer complete circle flat wire layer and completes the stator winding wiring at the assumed stator tray full layer.

[0006] Further, the variable pitch stepping feeding device includes a unwind buffer module, a straightening module, a feeding visual inspection module and a variable length wire feeding module; the unwind buffer module uses a double material roll and a counterweight buffer mechanism to supply the pre-calibrated flat wire raw material with constant tension; the straightening module includes multiple groups of horizontally arranged wire aligning mechanisms and vertically arranged wire shaping mechanisms arranged alternately for wire type straightening; the feeding visual inspection module includes a flat wire feeding camera and a flat wire feeding detection light source arranged on the visual inspection frame for detecting whether the wire type of the flat wire before paint removal meets the standard; the variable length wire feeding module uses a coding wheel mechanism to realize the stepping transmission of the flat wire according to the set length.

[0007] Further, the paint-removing self-detection module includes a triple-link drive mechanism, a multi-head paint-removing component arranged on the peeling frame, and a paint ash absorption component; the bottom of the peeling frame is mounted on the sliding top plate of the triple-link drive mechanism; the multi-head paint-removing component includes multiple groups of paint-removing heads, a paint-removing adjustment component, a paint-removing detection camera, and a paint-removing adapter; the paint-removing heads are mounted on the paint-removing adjustment component, the paint-removing detection camera is mounted on the paint-removing head, and the entire multi-head paint-removing module is mounted on the peeling frame through the paint-removing adapter.

[0008] Further, the wire-cutting module includes a wire-cutting mechanism, a material receiving pipe, a material 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 material receiving pipe is arranged at the material receiving port on the top plate of the wire-cutting bench, the lower end of the material receiving pipe is arranged facing the material 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.

[0009] Further, the flat wire forming device includes a 2D forming module, a 3D forming module, a forming vision detection module, a carbon brush detection module, a forming handling module, and a formed flat wire discharging module; the 2D forming module uses a bending mechanism to bend the cut flat wire segments; the 3D forming module uses a die pressing tower forming mechanism to realize module switching and die pressing forming of flat wires of different specifications; the forming vision detection module is used to detect whether the shape of the crown end of the flat wire after 3D die pressing forming meets the standard; the carbon brush detection module is used to detect the insulation of the 3D flat wire; the forming handling module uses translation, rotation, and clamping mechanisms to realize the transfer of the flat wire between different workstations; the formed flat wire discharging module receives the flat wire after die pressing forming.

[0010] Further, the die pressing tower forming mechanism of the 3D forming module includes multiple lower die components of different models mounted on the lower die mounting plate, multiple upper die components of different models mounted on the upper die mounting plate, a die pressing drive component, a sliding mounting plate, a lifting and switching component, and a fixed backplate 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 side to realize the 3D die pressing forming of the flat wire.

[0011] Further, the rotary single-layer wire inserting device includes a multi-station rotary table mechanism, a wire inserting position lifting and rotating mechanism, a material taking lifting mechanism, and a wire inserting anti-misoperation vision detection mechanism; the robotic wire inserting mechanism is used to clamp flat wire hairpins of different specifications and transport them above the wire inserting position of the multi-station rotary table mechanism; the multi-station rotary table mechanism is used to rotate and provide wire inserting workstations at different layers; the wire inserting position lifting and rotating mechanism and the material taking lifting mechanism are arranged below the multi-station rotary table mechanism and are used to rotate and assist in wire inserting at the upper wire inserting workstation or lift to facilitate full-circle material taking; the anti-misoperation vision detection mechanism is used to monitor the wire type and position of the flat wire hairpin to realize real-time judgment and feedback of misinsertion and missed insertion.

[0012] Further, the split wire insertion device includes a handling frame, a handling gripper turntable module, a stator wire winding module, and a split wire insertion detection module; the handling gripper turntable module is arranged on the top of the handling frame and is driven to traverse horizontally along the top of the frame, the stator wire winding module is arranged below the handling frame and receives the single-layer flat wire in a full circle supplied by the downward pressure of the handling gripper turntable module, and the split wire insertion detection module is arranged adjacent to the stator wire winding module to monitor the wire insertion state.

[0013] Further, the handling gripper turntable module includes a gripper top plate, a transfer top cylinder, an inner support mechanism, a pickup lower turntable mechanism, a lower turntable connection component, and a flat wire downward pressure mechanism; the transfer top cylinder is connected between the gripper top plate and the handling bottom plate of the handling frame, the inner support mechanism is connected to the gripper top plate from below, the pickup lower turntable mechanism is connected to the outer periphery of the inner support mechanism through the lower turntable connection component, and the downward pressure ring of the flat wire downward pressure mechanism is arranged to move up and down between the inner support mechanism and the pickup lower turntable mechanism.

[0014] Further, the stator wire winding module includes a wire winding frame, a wire winding top plate, a wire diameter adjustment mechanism, and a dummy stator tray; the wire winding top plate is arranged on the wire winding frame, the wire diameter adjustment mechanism is arranged at the middle wire winding hole of the wire winding top plate, and the dummy stator tray is arranged between the wire diameter adjustment mechanism and the wire winding top plate for collecting the flat wire in a full circle.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: The intelligent wire insertion system of the present application adopts advanced automation technology. The die pressing tower forming mechanism can quickly switch to adapt to 3D flat wires of different specifications and shapes. The split wire insertion is carried out in layers with a single-layer full circle as a unit, realizing the automatic grasping, arranging, and inserting of the flat wire coil, ensuring the accurate position and tight arrangement of the coil in the stator slot; the system real-time monitors and feedbacks the state of the enameled wire during the wire insertion process, avoiding scratches and damage, and ensuring that the wire insertion quality and motor performance meet the design requirements. This system significantly improves the manufacturing efficiency and quality of the flat wire motor, reduces the production cost, and can be popularized and applied in the manufacturing of drive motors for new energy vehicles or other motor manufacturing fields that require efficient and precise wire insertion. Description of the Drawings

[0016] Figure 1 and Figure 2 are schematic diagrams of different perspectives of the intelligent forming and wire insertion system for the stator flat wire of the present invention; Figure 3 is a schematic diagram of the wire feeding counterweight buffer mechanism; Figure 4 is a schematic diagram of the variable-length wire feeding module; Figure 5 is a schematic diagram of the de-inking 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 It is a schematic diagram of a 3D forming module; Figure 9 It is a schematic diagram of a forming vision inspection module; Figure 10 It is a partial structural schematic diagram of a carbon brush inspection module; Figure 11 It is a schematic diagram of a handling module; Figure 12 It is a schematic diagram of a blanking module; Figure 13 It is a schematic diagram of a manipulator wire insertion mechanism; Figure 14 It is a schematic diagram of a multi-station turntable mechanism; Figure 15 It is a schematic diagram of a hypothetical sub-tool; Figure 16 It is for Figure 15 partial exploded schematic diagram of; Figure 17 It is a schematic diagram of a wire insertion position lifting and rotating mechanism; Figure 18 It is a schematic diagram of a material taking lifting mechanism; Figure 19 It is a schematic diagram of a split wire insertion device; Figure 20 It is a schematic diagram of a handling frame; Figure 21 It is a schematic diagram of a handling jaw chuck module; Figure 22 It is a schematic diagram of an inner support mechanism; Figure 23 It is a partial structural schematic diagram of the inner support mechanism; Figure 24 It is a schematic diagram of a lower flower plate grabbing mechanism; Figure 25 It is a schematic diagram of a flat wire pressing mechanism; Figure 26 It is a schematic diagram of a stator wire winding module. Detailed implementation manners

[0017] 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.

[0018] An intelligent forming and wire insertion system for stator flat wires, see Figures 1 - 26, the system includes a variable pitch step feeding device, a paint removal self - detection module 50, a wire cutting module 60, a flat wire forming device, a robotic wire inserting mechanism 130, a rotary single - layer wire inserting device, a split - type wire inserting device, and a system controller arranged in sequence.

[0019] Arrangement relationship: The variable pitch step feeding device controllably provides the flat wire raw material after correction and visual inspection with variable - length steps. The paint removal self - detection module 50 uses a multi - head laser to remove the paint at the set position of the flat wire. The wire cutting module 60 cuts the flat wire at the paint - removed position. The flat wire forming device bends and presses the cut flat wire into shape and detects and screens it. The robotic wire inserting mechanism 130 picks up the formed flat wire and inserts it at the rotary single - layer wire inserting device to form a single - layer complete flat wire layer. The split - type wire inserting device receives the single - layer complete flat wire layer and completes the stator winding wiring when the assumed sub - tray is full.

[0020] Among them, the variable pitch step feeding device includes a unwind buffer module 10, a straightening module 20, a feeding visual inspection module 30, and a variable - length wire feeding module 40. The unwind buffer module 10 uses a double - reel and counterweight buffer mechanism to supply the pre - corrected flat wire raw material with constant tension. The straightening module 20 includes multiple groups of horizontally arranged wire straightening mechanisms 21 and vertically arranged wire shaping mechanisms 22 arranged alternately to straighten the wire shape. The feeding visual inspection module 30 includes a flat wire feeding camera and a flat wire feeding detection light source arranged on the visual inspection frame, which is used to detect whether the wire shape of the flat wire before paint removal meets the standard. The variable - length wire feeding module 40 uses an encoder wheel mechanism to realize the step - by - step feeding of the flat wire according to the set length.

[0021] See Figure 2 , the unwind buffer module 10 includes two groups of reel mechanisms 11, two material detection mechanisms 12, a wire extraction guiding mechanism 13, and a wire feeding counterweight buffer mechanism 14. The two groups of reel 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 reel mechanism 11. The wire extraction guiding mechanism 13 receives the flat wire supplied from the reel mechanism 11 and guides it.

[0022] See Figure 3 , the wire feeding counterweight buffer mechanism 14 of the unwind buffer module 10 includes a pre - correction 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. Further, the wire feeding counterweight buffer mechanism 14 also 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 feeding tension.

[0023] See Figure 4, 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 downward 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 downward pressing drive assembly 47, so as to convey the flat wire according to a set length.

[0024] Furthermore, the variable-length wire feeding module 40 further includes an alignment guide base 48.

[0025] Among them, referring to Figure 5 , the paint removal self-detection module 50 includes a triple-link drive mechanism 51, a multi-head paint removal assembly 54 and a paint dust absorption assembly 55 arranged on a peeling frame 53; the bottom of the peeling frame 53 is installed on the sliding top plate of the triple-link drive mechanism 51; the multi-head paint removal assembly 54 includes multiple groups of paint removal heads 541, a paint removal adjustment assembly 542, a paint removal detection camera 543 and a paint removal adapter base; the paint removal heads 541 are installed on the paint removal adjustment assembly 542, the paint removal detection camera 543 is installed on the paint removal head 541, and the entire multi-head paint removal module 54 is installed on the peeling frame 53 through the paint removal adapter base.

[0026] The paint removal self-detection module 50 further includes guide wire support modules 52 arranged on the front and rear sides of the peeling frame 53, and the bottoms of the two guide wire support modules 52 are installed on the sliding top plate of the triple-link drive mechanism 51.

[0027] The triple-link drive mechanism 51 includes a linkage driver, a wire dragging sliding base connecting the upper part to the guide wire support module, a peeling sliding base connecting the upper part to the peeling frame, and a variable pitch link group; the wire dragging sliding base and the peeling sliding base are slidably arranged at both ends of the bottom on the variable pitch linkage rail module, both ends of the variable pitch link group are fixed and connected to the wire dragging sliding base and the peeling sliding base in the middle through a linkage column, and the bottom of the peeling sliding base is further connected to the driving movable end of the linkage driver. When the linkage driver drives, the distance between the two guide wire support modules 52 and the peeling frame 53 is adjusted in a linkage manner.

[0028] Among them, four groups of paint removal heads 541 are adopted and have different powers. In the case of paint removal of symmetrical flat wire heads, the powers of the two opposite paint removal heads 541 are the same. In one example, the powers of the upper and lower paint removal heads 541 are greater than those of the left and right ones, so as to achieve the processing effect of a flat head rather than a square head.

[0029] The paint removal heads 541 adopt lasers, including a laser light source body and a laser transmission lens module. Referring to the attached drawings, the laser transmission lens emits the laser of the laser light source body and then passes through the processing window to perform laser paint removal on the head of the flat wire.

[0030] The paint removal adjustment component 542 adopts a linear slide or an angle slide, etc., and can also be in the form of other fine-tuning motors, etc., for adjusting the position and angle of the paint removal head 541.

[0031] The paint removal detection camera 543 is used to detect the peeling effect of the flat wire head after being processed by the paint removal head 541. Of course, a purge mechanism such as an air knife can also be set at the paint removal detection camera 543 to ensure the surface cleanliness of the detection lens.

[0032] The paint ash absorption module 55 includes a processing shield, multiple dust suction branch pipes, a dust suction main pipe and an external dust collector and exhaust fan. A wire transmission hole is opened in the middle of the processing shield and a processing window is opened on the side. The multiple dust suction branch pipes are connected to the processing shield in a cross-direction with the processing direction of the multi-head paint removal module 54. The multiple dust suction branch pipes are collected through the dust suction main pipe at the top of the peeling rack 53 and then connected to the external dust collector.

[0033] The paint removal self-detection module 50 also includes a guide cleaning module, which includes a guide groove block installed on the guide mounting base plate, two groups of correction wheel groups and a brush chamber arranged vertically front and back; the peeled flat wire passes through the correction wheel group and then passes through the brush chamber to clean the copper wire surface.

[0034] Among them, see Figure 6 The wire cutting module 60 includes a wire cutting mechanism 61, a material receiving pipe 62, a material receiving box 63, a wire cutting controller 64 and a wire cutting stand 65; the wire cutting mechanism 61 is arranged on the top plate of the wire cutting stand 65, the top end of the material receiving pipe 62 is arranged at the material receiving port on the top plate of the wire cutting stand 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 wire cutting stand 65 below, and the wire cutting controller 64 controls the wire cutting action of the wire cutting mechanism 61.

[0035] The tangent mechanism 61 includes a tangent drive, a tangent gearbox, a slide assembly, an upper cutter assembly, a lower cutter assembly, a wire assembly and a material break sensor; the upper cutter assembly and the lower cutter assembly are respectively installed on the output side of the tangent gearbox through the corresponding slide assemblies, and the tangent drive drives the upper cutter assembly to reciprocate toward the lower cutter assembly through the tangent gearbox, the wire assembly horizontally penetrates the middle of the tangent gearbox, and the material break sensor is arranged at the upper cutter assembly to monitor the cutting status.

[0036] The wire cutting mechanism 61 also includes an upper tube for dropping materials. A dropping hole is opened on the lower cutter assembly, and the upper end of the upper tube for dropping materials is connected to the dropping hole.

[0037] A tangent feeding mechanism 66 is also provided upstream of the tangent module 60 , and the tangent feeding mechanism 66 adopts a circulating slide rail conveying method to cyclically feed materials.

[0038] Among them, the flat wire forming device includes a 2D forming module 70, a 3D forming module 80, a forming vision inspection module 90, a carbon brush inspection module 100, a forming handling module 110, and a formed flat wire blanking module 120; the 2D forming module 70 uses a bending mechanism to bend the cut flat wire segment; the 3D forming module 80 uses a die pressing tower forming mechanism to achieve module switching and die pressing forming of flat wires of different specifications; the forming vision inspection module 90 is used to detect whether the shape of the crown end of the flat wire after 3D die pressing is up to standard; the carbon brush inspection module 100 is used to detect the insulation of the 3D flat wire; the forming handling module 110 uses translation, rotation, and clamping mechanisms to realize the transfer of the flat wire between different workstations; the formed flat wire blanking module 120 receives the flat wire after die pressing forming.

[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 and eccentrically arranged on the top surface of the bending disc 73, and the bending wire inlet assembly 75 horizontally conveys the flat wire above the middle of the bending opening of the bending reference plate 72.

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

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

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

[0043] Among them, referring to Figure 8 , the die pressing tower forming mechanism of 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 drive 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 overall lifting of the sliding mounting plate 86 to realize the switching of different models of dies at the processing position, and the die pressing drive assembly 85 drives the corresponding lower die component 81 and upper die component 82 to realize the 3D die pressing forming of the flat wire.

[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 types 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 an 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 a carbon brush tester body 103. Refer to the appendix Figure 1 .

[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 type 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 table frame 121, a slide rod wire frame 122 and a sliding material frame 123. The 3D flat wire, that is, the flat wire hairpin, after being inspected, is moved into the slide rod wire frame 122 or the sliding material frame 123 through the handling module 110.

[0050] Furthermore, a vibration discharging mechanism can also be set at the slide rod wire frame 122 to gradually feed the qualified formed flat wire by vibration. So as to facilitate the picking of the subsequent wire insertion.

[0051] Among them, referring to Figure 13, the manipulator wire inserting mechanism 130 includes a multi-axis robotic arm 131, a wire inserting lifting rod 132, and a flat wire clamp 133. The flat wire clamp 133 is installed at the end of the vertically arranged wire inserting lifting rod 132.

[0052] Among them, the rotary single-layer wire inserting device includes a multi-station turntable mechanism 140, a wire inserting position lifting and rotating mechanism 150, a material taking lifting mechanism 160, and a wire inserting anti-misoperation vision detection mechanism. The manipulator wire inserting mechanism 130 is used to clamp flat wire hairpins of different specifications and transport them above the wire inserting position of the multi-station turntable mechanism 140. The multi-station turntable mechanism 140 is used to rotatably provide wire inserting stations at different layers. The wire inserting position lifting and rotating mechanism 150 and the material taking lifting mechanism 160 are arranged below the multi-station turntable mechanism 140 and are used to rotate and assist in wire inserting or lift for full-circle material taking at the upper wire inserting stations. The anti-misoperation vision detection mechanism is used to monitor the wire type and position of the flat wire hairpin to realize real-time judgment and feedback of misinsertion and missed insertion.

[0053] Among them, referring to Figure 13 , the multi-axis robotic arm 311 adopts a four-axis robotic arm. The wire inserting lifting rod 132 is arranged in the form of a lead screw or a threaded rod on the end shaft of the four-axis robotic arm and is driven by the four-axis robotic arm to lift and lower, so as to realize the pressing down and lifting of the flat wire clamp 133. The four-axis robotic arm can rotate horizontally. After the flat wire clamp 133 clamps the flat wire hairpin, it is lifted and transferred above the wire inserting position of the multi-station turntable mechanism 140 for sequential pressing down and wire inserting.

[0054] Among them, referring to Figures 14 - 16 , the multi-station turntable mechanism 140 includes a turntable rotating seat 141, a multi-station turntable body 142, a plurality of assumed sub-toolings 143, and a tooling wire taking and positioning assembly 144. The lower part of the middle of the multi-station turntable body 142 is fixed to the turntable rotating seat 141 and is driven to rotate and switch stations. The plurality of assumed sub-toolings 143 are arranged at the wire inserting stations of the multi-station turntable body 142 and are controllably positioned by the tooling wire taking and positioning assembly 144.

[0055] Referring to Figure 15 and Figure 16 , the assumed sub-toolings 143 include a positioning groove chassis 1432 that slides up and down in the wire inserting cage frame 1431, a push plate 1433 with radially evenly distributed slots and positioning fins, and a through groove top plate 1434. The positioning groove chassis 1432 and the through groove top plate 1434 are supported and connected by an upper support column group 1435. The push plate 1433 is slidably arranged between the positioning groove chassis 1432 and the through groove top plate 1434 along the upper support column group 1435. A plurality of wire inserting lifting rods 1436 passing through the positioning groove chassis 1432 are connected to the bottom of the push plate 1433. Two rotating plates 1438 are connected from below the wire inserting cage frame 1431 to the bottom surface of the upper positioning groove chassis 1432.

[0056] The lower ends of multiple wire-inserting lifting rods 1436 are arranged on a wire-inserting lifting disc 1437 and are matched with the material-taking lifting mechanism 160 below.

[0057] A wire-taking positioning block is also arranged on the outer peripheral surface of the positioning groove chassis 1432, and a positioning pin hole is radially opened in the wire-taking positioning block 1439.

[0058] The wire-inserting cage frame 1431 includes a cage frame top ring, a cage frame bottom ring and cage frame support vertical rods. A positioning pin is arranged on the outer periphery of the cage frame bottom ring. The positioning pin is driven by the tooling wire-taking positioning assembly 144 to insert into or disengage from the pin hole of the wire-taking positioning block.

[0059] A plurality of radially evenly distributed wire-inserting side blocking pieces 1439 are also arranged between the positioning groove chassis 1432 and the through groove top disc 1434. The wire-inserting side blocking pieces 1439 pass through the radially evenly distributed slot grooves of the push plate 1433 of the positioning fin plate.

[0060] Among them, referring to Figure 17 , the wire-inserting position lifting and rotating mechanism 150 includes a lifting and rotating gantry frame 151, a lifting plate 152, a lifting driver 153, a rotating driver 154, a rotating adapter 155 and a rotating profiling part 156; the four corners of the bottom surface of the lifting plate 152 are slidably installed above the cross beam plate of the lifting and rotating gantry frame 151 through a guide column assembly 157. The lifting rods of two lifting drivers 153 pass through from below the cross beam plate of the lifting and rotating gantry frame 151 and are connected to both ends of the bottom surface of the lifting plate 152. The housing of the rotating driver 154 is fixed to the lifting plate 152, and the end of the rotating shaft of the rotating driver 154 is connected to the rotating adapter 155, so as to drive the rotating adapter 155 and the rotating profiling part 156 to rotate according to the design.

[0061] It is assumed that driving notch openings such as arc-shaped grooves and V-shaped grooves are opened at the bottom of the rotating plate 1438 of the sub-tool 143. The outer shape of the rotating profiling part 156 is adapted to the driving notch openings. For example, it is in the form of a shaft or a combination of a shaft and bearing rollers, and the rotating plate 1438 with an arc-shaped groove as the driving notch opening is matched with it.

[0062] Of course, the mechanism is also provided with a lifting and rotating limiting part, such as a rotating inductor, etc., which is convenient for intelligent control of lifting and rotation.

[0063] Among them, referring to Figure 18 , the material-taking lifting machine 160 includes a material-taking lifting gantry frame 161, a material-taking lifting driver 162 and a lifting head 163. The lifting head 163 is arranged at the end of the lifting rod of the material-taking lifting driver 162 that telescopically moves vertically upward.

[0064] The error-proofing vision detection mechanism includes a light curtain induction detection component and an optical camera detection component. Among them, the light curtain induction detection component is horizontally arranged facing the wire insertion position of the multi-station turntable mechanism 140, and the optical camera detection component is arranged above the middle of the multi-station turntable mechanism 140 and obliquely downward facing the wire insertion position.

[0065] Among them, referring to Figure 19 , the split wire insertion device includes a handling frame 170, a handling gripper turntable module 180, a stator wire winding module 190, and a split wire insertion detection module 200; the handling gripper turntable module 180 is arranged on the top of the handling frame 170 and is driven to horizontally move along the top of the frame, the stator wire winding module 180 is arranged below the handling frame 170 and receives the single-layer flat wire in a whole circle supplied by the downward pressure of the handling gripper turntable module 180, and the split wire insertion detection module 200 is arranged adjacent to the stator wire winding module 190 to monitor the wire insertion state.

[0066] Referring to Figure 20 , the handling frame 170 includes frame columns, a frame beam, a handling top plate, a handling translation drive assembly, a handling downward pressure drive mechanism, and a handling bottom plate; the handling top plate is driven by the handling translation drive assembly to horizontally slide on the frame beam; the handling downward pressure drive mechanism is arranged on the handling top plate, and the bottom end of the drive rod of the handling downward pressure drive mechanism is connected to the top surface of the handling bottom plate to realize the lifting of the handling bottom plate.

[0067] The handling frame also includes downward pressure lifting guide rods, downward pressure guide sleeves, and translation slide rail assemblies; multiple downward pressure lifting guide rods are vertically inserted through the handling top plate through the downward pressure guide sleeves, and the bottom of the downward pressure lifting guide rods is fixedly connected to the top surface of the handling bottom plate; two groups of translation slide rail assemblies are arranged on the corresponding frame beams, and the bottom surface of the handling top plate is connected to the two groups of translation slide rail assemblies and slides relative to the frame beam.

[0068] The handling translation drive assembly adopts a drive gear and rack method, a drive belt form, a linear motor drive method, etc., and preferably a drive gear and rack method here.

[0069] Among them, referring to Figure 21 , the handling gripper turntable module 180 includes a gripper top plate 181, a transfer top cylinder 182, an inner support mechanism 183, a grasping lower turntable mechanism 184, a lower turntable connection component 185, and a flat wire downward pressure mechanism 186; the transfer top cylinder 182 is connected between the gripper top plate 181 and the handling bottom plate 46 of the handling frame 40, the inner support mechanism 183 is connected to the gripper top plate 181 from below, the grasping lower turntable mechanism 184 is connected to the outer periphery of the inner support mechanism 183 through the lower turntable connection component 185, and the downward pressure ring of the flat wire downward pressure mechanism 186 is arranged to lift between the inner support mechanism 183 and the grasping lower turntable mechanism 184.

[0070] Among them, referring toFigure 22 and Figure 23 The inner support mechanism 183 includes an inner support pin 1831, an inner support plate 1832, an inner support cam disc assembly 1833, an inner support guide disc 1834, and an inner support driver 1835; the inner support plate 1832 is vertically arranged below the corresponding inner support pin 1831 to form an inner support circular array, the bottom of the inner support pin 1831 is embedded in the pin slot radially opened on the upper surface of the inner support guide disc 1834, the top of the inner support pin 1831 is connected to the cam in the inclined slot of the inner support cam disc assembly 1833, the cam disc of the inner support cam disc assembly 1833 is drivingly connected to the inner support driver 1835, and the inner support pin 1831 and the inner support plate 1832 are retracted or expanded by the rotation of the inner support cam disc assembly 1833.

[0071] Among them, referring to Figure 24 The lower flower disc grasping mechanism 184 includes an outer retracting push pin 1841, an outer retracting cam disc assembly 1842, an outer retracting driver 1843, a lower disc pin 1844, a tightening cam disc assembly 1845, a tightening driver 1846, and a double-sided guide groove disc 1847. The outer retracting push pins 1841 are arranged in a circular array in the upper guide groove of the double-sided guide groove disc 1847, and the lower disc pins 1844 are arranged in a circular array in the lower guide groove of the double-sided guide groove disc 1847; the top surface of the outer retracting push pin 1841 is connected to the cam in the inclined slot of the outer retracting cam disc assembly 1842, and the cam disc of the outer retracting cam disc assembly 1842 is drivingly connected to the outer retracting driver 1843; the bottom surface of the lower disc pin 1844 is connected to the cam in the inclined slot of the tightening cam disc assembly 1845, and the cam disc of the tightening cam disc assembly 1845 is drivingly connected to the tightening driver 1846.

[0072] Among them, the lower disc connection component 185 uses a perforated plate and a support column, as long as it can support and connect the inner support mechanism 183 and the lower flower disc grasping mechanism 184, and the specific structure will not be elaborated here.

[0073] Among them, referring to Figure 25 The flat wire pressing mechanism 186 includes a flat wire pressing driver 1861, a flat wire pressing pulley assembly 1862, a flat wire pressing lifting rod 1863, a flat wire pressing bottom plate 1864, and a flat wire pressing ring 1865. The flat wire pressing driver 1861 and the flat wire pressing pulley assembly 1862 are supported on the jaw top plate 181, the flat wire pressing lifting rod 1863 is vertically arranged and is drivingly connected to the flat wire pressing pulley assembly 1862, the flat wire pressing bottom plate 1864 is connected to the bottom end of the flat wire pressing lifting rod 1863, and the flat wire pressing ring 1865 is arranged below the flat wire pressing bottom plate 1864.

[0074] Furthermore, the flat wire pressing mechanism 186 further includes a pressing guide component 1866, which specifically adopts a combination mode of a guide rod and a guide sleeve, and will not be elaborated here.

[0075] Among them, referring to Figure 26 , the stator wire winding module 190 includes a wire winding frame 191, a wire winding top plate 192, a wire diameter adjusting mechanism 193, and a dummy stator tray 194; the wire winding top plate 192 is arranged on the wire winding frame 191, the wire diameter adjusting mechanism 193 is arranged at the middle wire winding hole of the wire winding top plate 192, and the dummy stator tray 194 is arranged between the wire diameter adjusting mechanism 193 and the wire winding top plate 192 for collecting a whole circle of flat wire.

[0076] Furthermore, the stator wire winding module 190 further includes a material receiving lifting mechanism 195; the material receiving lifting mechanism 195 is used to lift the wire winding top plate 192 on the wire winding frame 191 in a liftable manner.

[0077] The split wire insertion detection module 200 is arranged on the wire winding frame 191 and includes a material sensor, an insertion state monitoring camera, etc.

[0078] This system will adopt advanced automation technology, combined with visual intelligent detection, to realize the automatic grasping, arranging and inserting of flat wire coils, ensuring the accurate position and tight arrangement of the coils in the stator slots. At the same time, the system will also monitor and feedback the state of the enameled wire in real time during the wire insertion process, avoid scratching and damage, and ensure that the wire insertion quality and motor performance meet the design requirements. The specific advantages are as follows.

[0079] 1. The stator flat wire intelligent forming system of the present application can detect the feeding appearance, the wire type, size and damage after forming in real time, and can provide integrated comprehensive processing of flat wires with different lengths and different wire type specifications on the same system; 2. This system adopts advanced automation technology to realize the automatic grasping, arranging and inserting of flat wire coils, greatly improving the production efficiency and quality. This technological breakthrough solves the common manual wire insertion problem in the industry. Especially for the difficult changeover caused by large winding differences and low compatibility, this system has strong automatic adjustment ability, can adapt to a variety of different winding types, and reduces the dependence on manual operation.

[0080] 3. Compared with the existing overall wire cup wire insertion method, this system has higher flexibility and accuracy. The traditional overall wire insertion is more difficult in the final insertion of the winding, which is likely to lead to a reduction in the yield rate. The modular design of this system enables each coil to be inserted separately and accurately, avoiding the disadvantages of overall wire insertion and improving the accuracy of wire insertion and the overall performance of the motor.

[0081] 4. In terms of performance and quality, this system effectively avoids scratching and damage by monitoring and feedback the state of the enameled wire in real time during the wire insertion process, ensuring the stability of the wire insertion quality and motor performance. At the same time, the high automation and intelligence of the system also reduce the interference of human factors, further improving the reliability and consistency of the product.

[0082] 5. High technical flexibility. This system also has significant market adaptability advantages. With the rapid development of the new energy vehicle industry and the continuous expansion of the flat wire motor market, the demand for the wire insertion system is also becoming increasingly diverse. This intelligent wire insertion system can be customized and developed according to different requirements, providing flexible and diverse solutions to meet the diverse needs of the market.

[0083] 6. By means of improving production efficiency, reducing manufacturing costs, and increasing the yield rate, etc., this system will bring significant economic and social benefits, thus winning more competitive advantages in the market.

[0084] In summary, the automatic wire insertion system developed in this project has significant competitive advantages in the current domestic and international markets. It can not only solve the technical problems in the industry but also provide more efficient, reliable, and flexible wire insertion solutions for customers.

[0085] Currently, the wire insertion system is mainly applied to the manufacture of drive motors for new energy vehicles, but it can also be extended to other motor manufacturing fields that require efficient and precise wire insertion.

[0086] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended 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 described 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 present invention in each embodiment.

Claims

1. An intelligent forming and inserting wire system for stator flat wires, characterized in that: It includes a variable pitch step feeding device, a paint removing self - detection module (50), a wire cutting module (60), a flat wire forming device, a manipulator wire inserting mechanism (130), a rotary single - layer wire inserting device, a split - type wire inserting device, and a system controller arranged in sequence; The variable pitch step feeding device controllably provides the flat wire raw material after correction and visual inspection with variable - length steps. The paint removing self - detection module (50) uses multi - head lasers to remove the paint at the set position of the flat wire. The wire cutting module (60) cuts the flat wire at the paint - removed position. The flat wire forming device bends and presses the cut flat wire into shape and detects and screens it. The manipulator wire inserting mechanism (130) picks up the formed flat wire and inserts it at the rotary single - layer wire inserting device to form a single - layer complete circular flat wire layer. The split - type wire inserting device receives the single - layer complete circular flat wire layer and completes the stator winding wiring when the assumed sub - tray is full of layers.

2. The intelligent molding wiring system according to claim 1, wherein: The variable pitch step feeding device includes a unwind buffer module (10), a straightening module (20), a feeding visual inspection module (30), and a variable - length wire feeding module (40). The unwind buffer module (10) uses a double - coil and counterweight caching mechanism to supply the pre - corrected flat wire raw material with constant tension. The straightening module (20) includes multiple groups of horizontally arranged wire straightening mechanisms (21) and vertically arranged wire shaping mechanisms (22) arranged alternately for wire type straightening. The feeding visual inspection module (30) includes a flat wire feeding camera and a flat wire feeding detection light source arranged on the visual inspection frame, which is used to detect whether the wire type of the flat wire before paint removal meets the standard. The variable - length wire feeding module (40) uses an encoder wheel mechanism to realize the step - by - step feeding of the flat wire according to the set length.

3. The intelligent molding wire plugging system according to claim 1, wherein: The paint removing self - detection module (50) includes a three - linkage drive mechanism (51), a multi - head paint removing component (54) and a paint and ash absorption component (55) arranged on a paint - removing frame (53). The bottom of the paint - removing frame (53) is installed on the sliding top plate of the three - linkage drive mechanism (51). The multi - head paint removing component (54) includes multiple groups of paint removing heads (541), paint removing adjustment components (542), paint removing detection cameras (543), and paint removing adapters. The paint removing heads (541) are installed on the paint removing adjustment components (542), the paint removing detection cameras (543) are installed on the paint removing heads (541), and the entire multi - head paint removing module (54) is installed on the paint - removing frame (53) through the paint removing adapter.

4. The stator flat wire intelligent forming system according to claim 1, characterized in that: 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 opposite to the receiving box (63) on the bottom plate of the lower wire cutting bench (65). The wire cutting controller (64) controls the wire cutting action of the wire cutting mechanism (61).

5. The stator flat wire intelligent forming system according to claim 1, wherein: The flat wire forming device includes a 2D forming module (70), a 3D forming module (80), a forming vision inspection module (90), a carbon brush inspection module (100), a forming handling module (110), and a formed flat wire blanking module (120); the 2D forming module (70) uses a bending mechanism to bend the cut flat wire segments; the 3D forming module (80) uses a die pressing tower forming mechanism to achieve module switching and die pressing forming of flat wires of different specifications. The forming vision inspection module (90) is used to detect whether the shape of the crown end of the flat wire after 3D die pressing forming meets the standard; the carbon brush inspection module (100) is used to detect the insulation of the 3D flat wire; the forming handling module (110) uses translation, rotation, and clamping mechanisms to realize the transfer of the flat wire between different workstations; the formed flat wire blanking module (120) receives the flat wire after die pressing forming.

6. The stator flat wire intelligent forming system according to claim 5, wherein: The die pressing tower forming mechanism of 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 die pressing 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 die pressing drive component (85) drives the corresponding lower die component (81) and upper die component (82) to realize the 3D die pressing forming of the flat wire.

7. The stator flat wire intelligent forming system according to claim 1, characterized in that: The turntable type single-layer wire inserting device includes a multi-station turntable mechanism (140), a wire inserting position lifting and rotating mechanism (150), a material taking lifting mechanism (160), and a wire inserting anti-error vision inspection mechanism; the robotic wire inserting mechanism (130) is used to clamp flat wire hairpins of different specifications and transport them above the wire inserting position of the multi-station turntable mechanism (140); the multi-station turntable mechanism (140) is used to rotate and provide wire inserting workstations at different layers; the wire inserting position lifting and rotating mechanism (150) and the material taking lifting mechanism (160) are arranged below the multi-station turntable mechanism (140) to assist in wire inserting by rotating the upper wire inserting workstation or lifting for full-circle material taking; the anti-error vision inspection mechanism is used to monitor the wire type and position of the flat wire hairpin to realize real-time judgment and feedback of misinsertion and missed insertion.

8. The stator flat wire intelligent forming system according to claim 7, wherein: The split type wire inserting device includes a handling frame (170), a handling gripper turntable module (180), a stator wire winding module (190), and a split wire inserting inspection module (200); the handling gripper turntable module (180) is arranged at the top of the handling frame (170) and is driven to horizontally move along the top of the frame; the stator wire winding module (180) is arranged below the handling frame (170) and receives the full-circle single-layer flat wire supplied by the downward pressure of the handling gripper turntable module (180), and the split wire inserting inspection module (200) is arranged adjacent to the stator wire winding module (190) to monitor the wire inserting state.

9. The stator flat wire intelligent forming system according to claim 8, characterized in that: The transporting clamping jaw faceplate module (180) comprises a clamping jaw top plate (181), an adapter top cylinder (182), an inner support mechanism (183), a mechanism for grabbing the lower faceplate (184), a lower plate connecting assembly (185) and a flat line lower pressing mechanism (186); the adapter top cylinder (182) is connected between the clamping jaw top plate (181) and a transporting bottom plate (46) of a transporting running frame (40); the inner support mechanism (183) is connected to the clamping jaw top plate (181) from below; the mechanism for grabbing the lower faceplate (184) is connected to the outer periphery of the inner support mechanism (183) through the lower plate connecting assembly (185); and the lower pressing ring of the flat line lowering mechanism (186) is spatially lifted and lowered and arranged between the inner support mechanism (183) and the mechanism for grabbing the lower faceplate (184).

10. The stator flat wire intelligent forming system according to claim 8, characterized in that: The stator wire taking-up module (190) comprises a wire taking-up frame (191), a wire taking-up top plate (192), a wire diameter adjustment mechanism (193) and a hypothetical sub-tray (194); the wire taking-up top plate (192) is arranged on the wire taking-up frame (191), the wire diameter adjustment mechanism (193) is arranged at the middle wire taking-up hole of the wire taking-up top plate (192), and the hypothetical sub-tray (194) is arranged between the wire diameter adjustment mechanism (193) and the wire taking-up top plate (192) for collecting a whole circle of flat wire.

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