Intelligent forming and inserting system for stator flat wire

Abstract

The application provides a kind of intelligent forming plug-in system of stator flat wire, belong to the field of automobile intelligent manufacturing, including variable pitch stepping feeding device, controllable variable length stepping provides correction and visual inspection after flat wire raw material;Paint removal self-detection module, adopts multi-head laser to set position of flat wire and skin;Cutting line module cuts flat wire at the skinning place;Flat wire forming device, flat wire is bent and molded and detected and screened;Mechanical hand plug-in mechanism cooperates with single-layer plug-in device of rotating disc type and forms single-layer whole circle flat wire layer;Split plug-in device receives single-layer whole circle flat wire layer and fills layer in the dummy stator tray to complete stator winding wiring.The application adopts molding tower forming mechanism and can quickly switch forming module, and the layered plug-in of split plug-in cooperates with intelligent visual inspection to ensure the plug-in quality and efficiency, and can be popularized and applied in the manufacture of new energy automobile drive motor or other motor manufacturing fields requiring efficient and accurate plug-in.

Description

TECHNICAL FIELD

[0001] The application belongs to the field of intelligent manufacturing of automobiles, and particularly relates to an intelligent forming and inserting system for a stator flat wire. BACKGROUND

[0002] As one of the core components of new energy vehicles, the performance of a driving motor directly affects the power performance, economy and cruising range of the vehicle.

[0003] In recent years, flat wire motors have gradually become the preferred choice for new energy vehicle driving motors due to their high power density, high efficiency, low noise and good heat dissipation performance. However, the stator inserting process is a technical difficulty in the manufacturing process of flat wire motors. The traditional manual inserting method has problems such as low production efficiency, difficulty in guaranteeing slot fill rate, and easy scratching of enameled wire, which not only increases the manufacturing cost, but also affects the performance and reliability of the motor. Therefore, developing an efficient and accurate automatic inserting system is of great significance to improve the manufacturing quality and production efficiency of flat wire motors. SUMMARY

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

[0005] An intelligent forming and inserting system for a stator flat wire, comprising a variable-distance stepping feeding device, a paint removal self-detection module, a wire cutting module, a flat wire forming device, a mechanical hand inserting mechanism, a turntable type single-layer inserting device, a split type inserting device and a system controller arranged in sequence; the variable-distance stepping feeding device controllably provides variable-length stepping flat wire raw materials after correction and visual detection, the paint removal self-detection module uses a multi-head laser to remove the skin at the set position of the flat wire, the wire cutting module cuts the flat wire at the skin removal position, the flat wire forming device bends and molds the cut flat wire and detects and screens it, the mechanical hand inserting mechanism picks up the formed flat wire and inserts it at the turntable type single-layer inserting device to form a single-layer whole-circle flat wire layer, and the split type inserting device receives the single-layer whole-circle flat wire layer to complete the stator winding insertion on the dummy stator tray.

[0006] Further, the variable-distance stepping feeding device comprises a unwinding buffer module, a straightening module, a feeding visual detection module and a variable-length wire feeding module; the unwinding buffer module adopts a double spool and counterweight buffer mechanism to provide pre-corrected flat wire raw materials with constant tension; the straightening module comprises a plurality of groups of alternately arranged horizontal straightening mechanisms and vertical shaping mechanisms for straightening the wire type; the feeding visual detection module comprises a flat wire feeding camera and a flat wire feeding detection light source arranged on a visual detection frame, and is used to detect whether the flat wire type before paint removal meets the standard; and the variable-length wire feeding module adopts an encoding wheel mechanism to realize the step-by-step conveying of the flat wire according to the set length.

[0007] Further, the paint removal self-detection module comprises a three-linkage driving mechanism, a multi-head paint removal assembly arranged on the paint removal frame, and a paint dust suction assembly; the bottom of the paint removal frame is mounted on a sliding top plate of the three-linkage driving mechanism; the multi-head paint removal assembly comprises a plurality of paint removal heads, a paint removal adjusting assembly, a paint removal detection camera, and a paint removal adapter; the paint removal heads are mounted on the paint removal adjusting assembly, and the paint removal detection camera is mounted on the paint removal heads; the entire multi-head paint removal module is mounted on the paint removal frame through the paint removal adapter.

[0008] Further, the cutting line module comprises a cutting line mechanism, a receiving pipe, a receiving box, a cutting line controller, and a cutting line rack; the cutting line mechanism is arranged on a top plate of the cutting line rack; a top end of the receiving pipe is arranged at a receiving opening on the top plate of the cutting line rack; a lower end of the receiving pipe is arranged opposite to the receiving box on a bottom plate of the cutting line rack; and the cutting line controller controls the cutting action of the cutting line mechanism.

[0009] Further, the flat wire forming device comprises a 2D forming module, a 3D forming module, a forming visual detection module, a carbon brush detection module, a forming conveying module, and a forming flat wire unloading module; the 2D forming module adopts a bending mechanism to bend the flat wire segment after cutting; the 3D forming module adopts a mold pressing tower forming mechanism to realize module switching and mold pressing forming of different specifications of flat wires; the forming visual detection module is used to detect whether the shape of the flat wire crown after 3D mold pressing forming meets the standard; the carbon brush detection module is used to detect the insulation of the 3D flat wire; the forming conveying module adopts a translation, rotation, and clamping mechanism to realize the transfer of the flat wire between different stations; and the forming flat wire unloading module receives the flat wire after mold pressing forming.

[0010] Further, the mold pressing tower forming mechanism of the 3D forming module comprises a plurality of lower mold assembly components of different specifications mounted on a lower mold mounting plate, a plurality of upper mold assembly components of different specifications mounted on an upper mold mounting plate, a mold pressing driving assembly, a sliding mounting plate, a lifting switching assembly, and a fixed back plate frame; the lifting switching assembly drives the sliding mounting plate to lift as a whole to switch different specifications of molds in a processing position; and the mold pressing driving assembly drives the lower mold assembly component and the upper mold assembly component on the corresponding side to realize mold pressing 3D forming of the flat wire.

[0011] Further, the rotary table type single-layer wire inserting device comprises a multi-station rotary table mechanism, a wire inserting position jacking and rotating mechanism, a material taking jacking mechanism, and a wire inserting error prevention visual detection mechanism; the mechanical hand wire inserting mechanism is used to clamp and take flat wire taps of different specifications to above the wire inserting station of the multi-station rotary table mechanism; the multi-station rotary table mechanism is used to rotate to provide wire inserting stations of different layers; the wire inserting position jacking and rotating mechanism and the material taking jacking mechanism are arranged below the multi-station rotary table mechanism and are used to rotate to assist wire insertion or jacking to facilitate full-circle material taking; and the error prevention visual detection mechanism is used to monitor the shape and position of the flat wire tap to realize real-time judgment and feedback of wrong insertion and missed insertion.

[0012] Further, the split type wire inserting device comprises a carrying frame, a carrying jaw disc module, a stator wire collecting module and a split type wire inserting detection module; the carrying jaw disc module is arranged on the top of the carrying frame and is driven to move along the top of the frame, the stator wire collecting module is arranged below the carrying frame and receives the whole layer of flat wire supplied by the carrying jaw disc module, and the split type wire inserting detection module is arranged near the stator wire collecting module to monitor the wire inserting state.

[0013] Further, the carrying jaw disc module comprises a jaw top plate, an adapter top cylinder, an inner support mechanism, a grabbing lower disc mechanism, a lower disc connecting assembly and a flat wire pressing mechanism; the adapter top cylinder is connected between the jaw top plate and the carrying bottom plate of the carrying frame, the inner support mechanism is connected to the jaw top plate from below, the grabbing lower disc mechanism is connected to the outer periphery of the inner support mechanism through the lower disc connecting assembly, and the pressing ring of the flat wire pressing mechanism is arranged to be lifted between the inner support mechanism and the grabbing lower disc mechanism.

[0014] Further, the stator wire collecting module comprises a wire collecting frame, a wire collecting top plate, a wire diameter adjusting mechanism and a dummy stator tray; the wire collecting top plate is arranged on the wire collecting frame, the wire diameter adjusting mechanism is arranged at the middle wire collecting hole of the wire collecting top plate, and the dummy stator tray is arranged between the wire diameter adjusting mechanism and the wire collecting top plate to collect the whole layer of flat wire.

[0015] Compared with the prior art, the intelligent wire inserting system has the advantages that the intelligent wire inserting system adopts advanced automatic technology, the mold pressing tower forming mechanism quickly switches to adapt to different specifications and shapes of 3D flat wires, the split type wire inserting is carried out in a single layer whole circle as a unit, the automatic grabbing, arranging and inserting of the flat wire coil are realized, the accurate position and close arrangement of the coil in the stator slot are ensured, the enameled wire state in the wire inserting process is monitored and fed back in real time, the scratching and damage are avoided, and the wire inserting quality and motor performance meet the design requirements. The 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 of new energy vehicles or other motor manufacturing fields requiring efficient and accurate wire inserting. BRIEF DESCRIPTION OF DRAWINGS

[0016] Figure 1 and Figure 2 FIG. 1 is a schematic view of the intelligent forming and wire inserting system of the stator flat wire from different perspectives of the application;

[0017] Figure 3 FIG. 6 is a schematic view of the wire feeding counterweight buffer mechanism;

[0018] Figure 4 FIG. 7 is a schematic view of the variable length wire feeding module;

[0019] Figure 5 FIG. 8 is a schematic view of the paint removal and self-detection module;

[0020] Figure 6 is a schematic diagram of a tangential module;

[0021] Figure 7 is a schematic diagram of a 2D forming module;

[0022] Figure 8 is a schematic diagram of a 3D forming module;

[0023] Figure 9 is a schematic diagram of a forming vision inspection module;

[0024] Figure 10 is a schematic diagram of a partial structure of a carbon brush inspection module;

[0025] Figure 11 is a schematic diagram of a carrying module;

[0026] Figure 12 is a schematic diagram of a blanking module;

[0027] Figure 13 is a schematic diagram of a mechanical hand wire insertion mechanism;

[0028] Figure 14 is a schematic diagram of a multi-station turntable mechanism;

[0029] Figure 15 is a schematic diagram of a dummy sub-tool;

[0030] Figure 16 is a partial exploded schematic diagram of Figure 15 ;

[0031] Figure 17 is a schematic diagram of a wire insertion position jacking and rotating mechanism;

[0032] Figure 18 is a schematic diagram of a material taking jacking mechanism;

[0033] Figure 19 is a schematic diagram of a split type wire insertion device;

[0034] Figure 20 is a schematic diagram of a carrying rack;

[0035] Figure 21 is a schematic diagram of a carrying jaw chuck module;

[0036] Figure 22 is a schematic diagram of an inner support mechanism;

[0037] Figure 23 is a schematic diagram of a partial structure of an inner support mechanism;

[0038] Figure 24 is a schematic diagram of a chucking lower chuck mechanism;

[0039] Figure 25A schematic view of a flat wire pressing mechanism is shown in Fig. 1.

[0040] Figure 26 A schematic view of a stator wire collecting module is shown in Fig. 4. DETAILED DESCRIPTION

[0041] In order to make the purposes, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protection scope of the present application.

[0042] An intelligent forming and inserting system for a stator flat wire is shown in Fig. 1. Figures 1-26 The system comprises a variable-length stepping feeding device, a paint removal self-detection module 50, a wire cutting module 60, a flat wire forming device, a mechanical hand wire inserting mechanism 130, a turntable type single-layer wire inserting device, a split type wire inserting device and a system controller arranged in sequence.

[0043] Arrangement relationship: The variable-length stepping feeding device provides the corrected and visually detected flat wire raw material, the paint removal self-detection module 50 uses a multi-head laser to remove the skin of the flat wire at a set position, the wire cutting module 60 cuts the flat wire at the skin removal position, the flat wire forming device bends and molds the cut flat wire and detects and screens it, the mechanical hand wire inserting mechanism 130 picks up the formed flat wire and inserts the wire at the turntable type single-layer wire inserting device to form a single-layer whole-circle flat wire layer, and the split type wire inserting device receives the single-layer whole-circle flat wire layer to complete the stator winding wire arrangement.

[0044] The variable-length stepping feeding device comprises a unwinding and buffering module 10, a straightening module 20, a feeding visual detection module 30 and a variable-length wire feeding module 40. The unwinding and buffering module 10 uses a double spool and counterweight buffering mechanism to provide the pre-corrected flat wire raw material with constant tension. The straightening module 20 comprises a plurality of groups of alternately arranged horizontal straightening mechanisms 21 and vertical shaping mechanisms 22 to straighten the wire type. The feeding visual detection module 30 comprises a flat wire feeding camera and a flat wire feeding detection light source arranged on a visual detection frame 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 encoding wheel mechanism to realize the stepping transmission of the flat wire according to the set length.

[0045] The system comprises a variable-length stepping feeding device, a paint removal self-detection module 50, a wire cutting module 60, a flat wire forming device, a mechanical hand wire inserting mechanism 130, a turntable type single-layer wire inserting device, a split type wire inserting device and a system controller arranged in sequence. Figure 2The unwinding buffer module 10 includes two groups of material roll mechanisms 11, two material detection mechanisms 12, a wire drawing guide mechanism 13, and a wire feeding counterweight buffer mechanism 14. The two groups of material roll mechanisms 11 provide continuous feeding by switching connection when there is no material. The material detection mechanism 12 detects the remaining state of the flat wire corresponding to the material roll mechanism 11. The wire drawing guide mechanism 13 receives the flat wire supplied from the material roll mechanism 11 and guides it.

[0046] Referring to Figure 3 The wire feeding counterweight buffer mechanism 14 of the unwinding buffer module 10 includes a pre-correction assembly 141, a constant tension 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 assembly 144, which is used to measure the lifting height of the counterweight wheel set, facilitating the control of the flat wire feeding tension.

[0047] Referring to Figure 4 The variable-length wire feeding module 40 includes a calibration frame 41, a lower encoder seat 42, an encoder wheel driving assembly 43, a lower encoder wheel 44, an upper encoder wheel 45, an upper encoder seat 46, and a lower pressing driving assembly 47. The lower encoder seat 42 is installed on the calibration frame 41. The lower encoder wheel 44 is installed on the lower encoder seat 44 and is driven to rotate by the encoder wheel driving assembly 43. The upper encoder wheel 45 is installed on the upper encoder seat 46 and drives the upper encoder seat 46 to move up and down, thereby feeding the flat wire at a set length.

[0048] Further, the variable-length wire feeding module 40 also includes an alignment guide seat 48.

[0049] Referring to Figure 5 The paint removal self-detection module 50 includes a three-link driving mechanism 51, a multi-head paint removal assembly 54 arranged on a peeling frame 53, and a paint dust suction assembly 55. The bottom of the peeling frame 53 is installed on the sliding top plate of the three-link driving mechanism 51. The multi-head paint removal assembly 54 includes multiple paint removal heads 541, a paint removal adjustment assembly 542, a paint removal detection camera 543, and a paint removal adapter seat. The paint removal heads 541 are installed on the paint removal adjustment assembly 542, and the paint removal detection camera 543 is installed on the paint removal heads 541. The entire multi-head paint removal module 54 is installed on the peeling frame 53 through the paint removal adapter seat.

[0050] The paint removal self-detection module 50 also includes guide wire holding modules 52 arranged on the front and rear sides of the peeling frame 53. The bottoms of the two guide wire holding modules 52 are installed on the sliding top plate of the three-link driving mechanism 51.

[0051] The triple linkage driving mechanism 51 includes a linkage driver, a top connection guiding and supporting wire module sliding base, a top connection peeling frame peeling sliding base, and a variable distance linkage group. The top connection guiding and supporting wire module sliding base and the top connection peeling frame peeling sliding base are slidably arranged at both ends of the variable distance linkage sliding rail module. The variable distance linkage group is fixed at both ends and connected to the top connection guiding and supporting wire module sliding base and the top connection peeling frame peeling sliding base through the linkage column in the middle. The top connection peeling frame peeling sliding base is further connected to the driving active end of the linkage driver. When the linkage driver is driven, the distance between the two guiding and supporting wire modules 52 and the peeling frame 53 is adjusted.

[0052] Among them, the paint stripping head 541 adopts four groups, and the power is different. In the case of needing to strip paint symmetrically on the flat wire head, the power of the opposite two paint stripping heads 541 is the same. In an example, the power of the upper and lower two paint stripping heads 541 is greater than that of the left and right two, so as to achieve the processing effect of flat head instead of square head.

[0053] The paint stripping head 541 adopts a laser, including a laser light source body and a laser transmission lens module. Referring to the drawings, the laser transmission lens transmits the laser emitted by the laser light source body to the flat wire head for paint stripping.

[0054] The paint stripping adjusting assembly 542 adopts a linear slide or an angle slide, or other fine adjustment motors, etc., for adjusting the position and angle of the paint stripping head 541.

[0055] The paint stripping detection camera 543 is used to detect the peeling effect of the flat wire head after processing by the paint stripping head 541. Of course, a blowing mechanism such as a air knife can also be provided at the paint stripping detection camera 543 to ensure the cleanliness of the detection lens.

[0056] The paint dust absorption module 55 includes a processing shield, a plurality of dust suction branch pipes, a dust suction main pipe, and an externally connected dust collector and an air suction machine. The processing shield is provided with a wire conveying hole in the middle and a processing window on the side. The plurality of dust suction branch pipes are communicated to the processing shield in the processing direction of the multi-head paint stripping module 54. The plurality of dust suction branch pipes are connected to the externally connected dust collector after being collected through the dust suction main pipe at the top of the peeling frame 53.

[0057] The paint stripping self-detection module 50 further includes a guide and cleaning module, which includes a guide groove block mounted on a guide mounting base plate, two groups of front and rear vertical correction wheel groups, and a brush chamber. The flat wire after peeling passes through the brush chamber for copper wire surface cleaning after the correction wheel group.

[0058] Among them, referring to Figure 6The 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, and 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.

[0059] 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 assembly, and the tangent drive drives the upper cutter assembly to move back and forth toward the lower cutter assembly through the tangent gearbox. The wire assembly horizontally passes through the middle of the tangent gearbox, and the material break sensor is arranged at the upper cutter assembly to monitor the cutting status.

[0060] The cutting mechanism 61 further includes an upper blanking tube, a blanking hole is provided on the lower cutter assembly, and the upper end of the upper blanking tube is connected to the blanking hole.

[0061] A tangent loading mechanism 66 is further provided upstream of the tangent module 60 , and the tangent loading mechanism 66 adopts a circulating slide rail conveying method for cyclic loading.

[0062] Among them, the flat wire forming device includes a 2D forming module 70, a 3D forming module 80, a forming visual inspection module 90, a carbon brush detection module 100, a forming and handling module 110 and a forming flat wire discharging module 120; the 2D forming module 70 adopts a bending mechanism to bend the cut flat wire segments; the 3D forming module 80 adopts a molding tower forming mechanism to realize module switching and molding of flat wires of different specifications; the forming visual inspection module 90 is used to detect whether the crown end shape of the flat wire after 3D molding meets the standards; the carbon brush detection module 100 is used to detect the insulation of the 3D flat wire; the forming and handling module 110 adopts translation, rotation and clamping mechanisms to realize the transfer of the flat wire between different workstations; the molding flat wire discharging module 120 receives the flat wire after molding.

[0063] Among them, see Figure 7 The 2D forming module 70 includes a 2D bending main support plate 71, a bending reference plate 72, a bending disk 73 provided with a bending wheel shaft 74, and a bending feed assembly 75; the bending reference plate 72 with a bending opening in the middle is buckled to the top of the 2D bending main support plate 71, and the bending disk 73 is driven to rotate and rise and fall along the bending opening; the bending wheel shaft 74 is eccentrically vertically arranged on the top surface of the bending disk 73, and the bending feed assembly 75 conveys the flat wire horizontally in the middle above the bending opening of the bending reference plate 72.

[0064] The 2D forming module 70 further comprises a bending support plate 76, which 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.

[0065] The 2D forming module 70 further comprises a rotating driving assembly 77 for rotating driving of the bending disc 73.

[0066] The 2D forming module 70 further comprises a lifting driving assembly 78 and a floating support frame 79, the lifting rod end top 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 rotating driving assembly 77, and the lifting driving assembly 78 drives the lifting rod to drive the synchronous lifting of the rotating driving assembly 77, the floating support frame 79 and the bending disc 73.

[0067] Among them, referring to Figure 8 The mold pressing tower forming mechanism of the 3D forming module 80 comprises a plurality of lower mold assemblies 81 of different models installed on the lower mold mounting plate 83, a plurality of upper mold assemblies 82 of different models installed on the upper mold mounting plate 84, a mold pressing driving assembly 85, a sliding mounting plate 86, a lifting switching assembly 87 and a fixed back plate frame 88; the lifting switching assembly 87 drives the overall lifting of the sliding mounting plate 86 to realize the switching of different models of molds in the processing position, and the mold pressing driving assembly 85 drives the lower mold assembly 81 and the upper mold assembly 82 on the corresponding side to realize the mold pressing 3D forming of the flat wire.

[0068] Among them, referring to Figure 9 The forming visual detection module 90 comprises a forming visual detection frame 91, a forming detection camera 92 and a forming detection backlight source 93, which is used for detecting whether the overall size and line type of the flat wire after 3D forming meet the standards.

[0069] Among them, referring to Figure 10 The carbon brush detection module 100 comprises a carbon brush detector 101 arranged on an insulation detection frame 102.

[0070] 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, referring to the attached Figure 1 .

[0071] Among them, referring to Figure 11, the carrying module 110 includes a 2D longitudinal carrying module 111, a 2D flat wire clamping rotating mechanism 112, a 3D longitudinal carrying module 113, a 2D flat wire single-leg clamping mechanism 114, a 3D flat wire double-leg clamping mechanism 115, a 3D detection clamping mechanism 116, a 3D temporary storage clamping mechanism 117, a 3D longitudinal carrying module 118 of blanking, and a 3D wire clamping rotating mechanism 119; the 2D flat wire clamping rotating mechanism 112 moves longitudinally along the 2D longitudinal carrying module 111 and rotates to change direction, and the 2D flat wire is transferred to the 2D flat wire single-leg clamping mechanism 114.

[0072] The 2D flat wire single-leg clamping mechanism 114, the 3D flat wire double-leg clamping mechanism 115, and the 3D detection clamping mechanism 116 move longitudinally along the 3D longitudinal carrying module 113, the 3D flat wire double-leg clamping mechanism 115 receives the 3D flat wire processed by the 3D forming module 80, longitudinally moves to the 3D temporary storage clamping mechanism 117 for temporary storage or the line type and size detection of the forming vision detection module 90, the 3D detection clamping mechanism 116 receives the detected 3D flat wire and longitudinally moves to the 3D wire clamping rotating mechanism 119, and the 3D wire clamping rotating mechanism 119 moves the 3D flat wire to the end and blanks at the blanking module 120.

[0073] Among them, referring to Figure 12 The blanking module 120 includes a blanking rack 121, a sliding pole wire rack 122, and a sliding material frame 123, and the 3D flat wire, that is, the flat wire hairpin, is moved into the sliding pole wire rack 122 or the sliding material frame 123 after detection by the carrying module 110.

[0074] Further, a vibration discharging mechanism can also be provided at the sliding pole wire rack 122 to gradually discharge the qualified formed flat wire by vibration, so as to facilitate the pickup of subsequent wire insertion.

[0075] Among them, referring to Figure 13 The manipulator wire insertion mechanism 130 includes a multi-axis manipulator 131, a wire insertion lifting rod 132, and a flat wire clamp 133, and the flat wire clamp 133 is installed at the end of the vertically arranged wire insertion lifting rod 132.

[0076] Among them, the rotary single-layer wire insertion device includes a multi-station rotary table mechanism 140, a wire insertion position jacking rotating mechanism 150, a material taking jacking mechanism 160, and a wire insertion mistake-proof vision detection mechanism; the manipulator wire insertion mechanism 130 is used for clamping different specifications of flat wire hairpins and transporting them to above the wire insertion position of the multi-station rotary table mechanism 140; the multi-station rotary table mechanism 140 is used for rotating to provide different layers of wire insertion stations; the wire insertion position jacking rotating mechanism 150 and the material taking jacking mechanism 160 are arranged below the multi-station rotary table mechanism 140 and are used for rotating to assist wire insertion or jacking to facilitate full-circle material taking; and the mistake-proof vision detection mechanism is used for monitoring the line type and position of the flat wire hairpin, realizing real-time judgment and feedback of wrong insertion and missed insertion.

[0077] Wherein, referring to Figure 13 , the multi-axis mechanical arm 311 adopts a four-axis mechanical arm, the wire inserting lifting rod 132 is in the form of a screw rod or a threaded rod and is arranged on the terminal shaft of the four-axis mechanical arm and is driven to lift by the four-axis mechanical arm, so as to realize the pressing and lifting of the flat wire clamp 133. The four-axis mechanical arm can rotate horizontally, and the flat wire clamp 133 clamps the flat wire hairpin, lifts and shifts to above the wire inserting position of the multi-station turntable mechanism 140, and performs sequential pressing and wire inserting.

[0078] Wherein, referring to Figures 14-16 , the multi-station turntable mechanism 140 comprises a turntable rotating seat 141, a multi-station turntable body 142, a plurality of hypothetical sub-tools 143 and a tool wire taking positioning assembly 144; the multi-station turntable body 142 is fixed to the turntable rotating seat 141 below the middle part and is driven to rotate and switch the station, the plurality of hypothetical sub-tools 143 are arranged on the wire inserting station of the multi-station turntable body 142 and are controllably positioned by the tool wire taking positioning assembly 144.

[0079] Referring to Figure 15 and Figure 16 , the hypothetical sub-tool 143 comprises a positioning groove bottom plate 1432 sliding up and down in a wire inserting cage 1431, a push plate 1433 with radially distributed insertion grooves and positioning fins and a through groove top plate 1434; the positioning groove bottom plate 1432 and the through groove top plate 1434 are supported and connected by an upper support column group 1435, the push plate 1433 is arranged between the positioning groove bottom plate 1432 and the through groove top plate 1434 and slides along the upper support column group 1435, a plurality of wire inserting jacking rods 1436 pass through the positioning groove bottom plate 1432 and are connected to the bottom of the push plate 1433; two rotating plates 1438 are connected to the bottom surface of the positioning groove bottom plate 1432 from below the wire inserting cage 1431.

[0080] The lower ends of the plurality of wire inserting jacking rods 1436 are arranged on a wire inserting jacking disc 1437 and match the material taking jacking mechanism 160 below.

[0081] A wire taking positioning block is further arranged on the outer circumferential surface of the positioning groove bottom plate 1432, and a positioning pin hole is radially arranged in the wire taking positioning block 1439.

[0082] The wire inserting cage 1431 comprises a cage top ring, a cage bottom ring and a cage support vertical rod, a positioning pin is arranged on the outer periphery of the cage bottom ring, and the positioning pin is driven by the tool wire taking positioning assembly 144 to make the positioning pin insert into or separate from the pin hole of the wire taking positioning block.

[0083] A plurality of wire inserting side baffles 1439 radially distributed between the positioning groove bottom plate 1432 and the through groove top plate 1434 pass through the radially distributed insertion grooves of the push plate 1433 of the positioning fins.

[0084] Wherein, referring to Figure 17 , the plug-wiring position jacking and rotating mechanism 150 comprises a jacking and rotating gantry 151, a jacking plate 152, jacking drives 153, a rotating drive 154, a rotating adapter 155 and a rotating profile 156; the jacking plate 152 is slidably mounted to the top of the beam plate of the jacking and rotating gantry 151 through the guide column assembly 157 at the bottom of four corners, the jacking rods of the two jacking drives 153 are connected to the bottom of the two ends of the jacking plate 152 after passing through the bottom of the beam plate of the jacking and rotating gantry 151, the housing of the rotating drive 154 is fixed to the jacking plate 152, and the rotating shaft end of the rotating drive 154 is connected to the rotating adapter 155, so as to drive the rotating adapter 155 and the rotating profile 156 to rotate according to the design.

[0085] It is assumed that the bottom of the rotating plate 1438 of the sub-tool 143 is provided with a driving slot such as an arc-shaped slot or a V-shaped slot, and the shape of the rotating profile 156 is matched with the driving slot, for example, in the form of a shaft or a shaft and a bearing roller, and the rotating plate 1438 with the arc-shaped slot is matched therewith.

[0086] Of course, the mechanism is also provided with jacking and rotating limiters, such as rotating inductors, to facilitate intelligent control of lifting and rotation.

[0087] Wherein, referring to Figure 18 , the material taking jacking machine 160 comprises a material taking jacking gantry 161, material taking jacking drives 162 and a jacking head 163, and the jacking head 163 is arranged at the end of the lifting rod of the vertically upward telescopic material taking jacking drives 162.

[0088] The mistake-proof visual detection mechanism comprises a light curtain inductive detection assembly and an optical camera detection assembly, wherein the light curtain inductive detection assembly is horizontally arranged towards the plug-wiring position of the multi-station turntable mechanism 140, and the optical camera detection assembly is arranged above the middle part of the multi-station turntable mechanism 140 and obliquely downwards towards the plug-wiring position.

[0089] Wherein, referring to Figure 19 , the split plug-wiring device comprises a carrying gantry 170, a carrying jaw disc module 180, a stator wire collecting module 190 and a split plug-wiring detection module 200; the carrying jaw disc module 180 is arranged at the top of the carrying gantry 170 and is driven to move along the top of the rack, the stator wire collecting module 190 is arranged below the carrying gantry 170 and receives the whole-circle single-layer flat wire supplied by the carrying jaw disc module 180, and the split plug-wiring detection module 200 is arranged adjacent to the stator wire collecting module 190 to monitor the plug-wiring state.

[0090] Referring to Figure 20, the moving frame 170 comprises a moving frame column, a moving frame beam, a moving top plate, a moving translation driving assembly, a moving downward driving mechanism and a moving bottom plate; the moving top plate is horizontally slid on the moving frame beam driven by the moving translation driving assembly; the moving downward driving mechanism is arranged on the moving top plate, and a bottom end of a driving rod of the moving downward driving mechanism is connected to a top surface of the moving bottom plate, so as to realize the lifting of the moving bottom plate.

[0091] The moving frame further comprises a downward lifting guide rod, a downward guide sleeve and a translation sliding rail assembly; a plurality of downward lifting guide rods are vertically inserted into the moving top plate through the downward guide sleeve, and bottom parts of the downward lifting guide rods are fixedly connected to the top surface of the moving bottom plate; two groups of translation sliding rail assemblies are arranged on corresponding moving frame beams, and the bottom surface of the moving top plate is connected to the two groups of translation sliding rail assemblies and slides relative to the moving frame beams.

[0092] The moving translation driving assembly adopts a driving gear and rack mode, a driving belt form, a linear motor driving mode or the like, and the driving gear and rack mode is preferred here.

[0093] Among them, referring to Figure 21 , the moving gripper disc module 180 comprises a gripper top plate 181, an adapter top sleeve 182, an inner support mechanism 183, a grabbing lower disc mechanism 184, a lower disc connecting assembly 185 and a flat wire downward pressing mechanism 186; the adapter top sleeve 182 is connected between the gripper top plate 181 and the moving bottom plate 46 of the moving frame 40, the inner support mechanism 183 is connected to the gripper top plate 181 from below, the grabbing lower disc mechanism 184 is connected to the outer periphery of the inner support mechanism 183 through the lower disc connecting assembly 185, and the downward pressing ring of the flat wire downward pressing mechanism 186 is vertically arranged between the inner support mechanism 183 and the grabbing lower disc mechanism 184.

[0094] Among them, referring to Figure 22 and Figure 23 , the inner support mechanism 183 comprises 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 part of the inner support pin 1831 is embedded into the pin slot radially formed in the upper surface of the inner support guide disc 1834, the top part of the inner support pin 1831 is connected with 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 with 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.

[0095] Among them, referring to Figure 24The mechanism 184 for grabbing the lower disc includes an outward-retracting push pin 1841, an outward-retracting cam disc assembly 1842, an outward-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 circular array of the outward-retracting push pin 1841 is arranged in the upper guide groove of the double-sided guide groove disc 1847, and the circular array of the lower disc pin 1844 is arranged in the lower guide groove of the double-sided guide groove disc 1847; the top surface of the outward-retracting push pin 1841 is connected to the cam in the oblique groove of the outward-retracting cam disc assembly 1842, and the cam disc of the outward-retracting cam disc assembly 1842 is driven and connected to the outward-retracting driver 1843; the bottom surface of the lower disc pin 1844 is connected to the cam in the oblique groove of the tightening cam disc assembly 1845, and the cam disc of the tightening cam disc assembly 1845 is driven and connected to the tightening driver 1846.

[0096] Among them, the lower plate connection component 185 adopts a perforated plate and a supporting column. As long as it can support and connect the internal support mechanism 183 and the lower disc grabbing mechanism 184, the specific structure will not be repeated here.

[0097] Among them, see Figure 25 The flat line depressing mechanism 186 includes a flat line depressing driver 1861, a flat line depressing pulley assembly 1862, a flat line depressing lifting rod 1863, a flat line depressing base plate 1864 and a flat line depressing ring 1865. The flat line depressing driver 1861 and the flat line depressing pulley assembly 1862 are supported on the clamping jaw top plate 181. The flat line depressing lifting rod 1863 is vertically arranged and is transmission-connected to the flat line depressing pulley assembly 1862. The flat line depressing base plate 1864 is connected to the bottom end of the flat line depressing lifting rod 1863. The flat line depressing ring 1865 is arranged below the flat line depressing base plate 1864.

[0098] Furthermore, the flat wire downward pressing mechanism 186 also includes a downward pressing guide assembly 1866, which specifically adopts a combination of a guide rod and a guide sleeve, which will not be described in detail here.

[0099] Among them, see Figure 26 The stator wire taking-up module 190 includes 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.

[0100] Furthermore, the stator wire-taking module 190 further includes a material-taking-up lifting mechanism 195 ; the material-taking-up lifting mechanism 195 is used to set the wire-taking top plate 192 on the wire-taking frame 191 in a liftable manner.

[0101] The split wire insertion detection module 200 is set on the wire take-up frame 191, and includes a material sensor, a wire insertion status monitoring camera, etc.

[0102] This system utilizes advanced automation technology, combined with intelligent visual inspection, to automatically grasp, arrange, and insert flat wire coils, ensuring accurate positioning and tight alignment of the coils in the stator slots. The system also provides real-time monitoring and feedback on the condition of the enameled wire during the insertion process, preventing scratches and damage and ensuring that insertion quality and motor performance meet design requirements. Specific advantages are as follows.

[0103] 1. The stator flat wire intelligent forming system of this application can detect the appearance of the feeding material, the wire shape after forming, the size and damage in real time, and can provide integrated comprehensive processing of flat wires of different lengths and wire shapes on the same system;

[0104] 2. This system utilizes advanced automation technology to automate the grabbing, arrangement, and insertion of flat wire coils, significantly improving production efficiency and quality. This technological breakthrough addresses the widespread manual wire insertion problem in the industry, particularly the difficulty in changing winding types due to large winding variations and low compatibility. The system's strong automatic adjustment capabilities allow it to adapt to a variety of winding types, reducing reliance on manual operation.

[0105] 3. Compared to the existing method of inserting wires through the coil cup as a whole, this system offers greater flexibility and precision. Traditional whole-cup insertion presents significant difficulties during the final insertion of the winding, which can lead to reduced yield. The modular design of this system allows each coil to be inserted individually and precisely, avoiding the drawbacks of whole-cup insertion and improving insertion accuracy and overall motor performance.

[0106] 4. In terms of performance and quality, this system effectively avoids scratches and damage by providing real-time monitoring and feedback on the enameled wire's condition during the insertion process, ensuring insertion quality and the stability of motor performance. Furthermore, the system's high degree of automation and intelligence reduces human interference, further improving product reliability and consistency.

[0107] 5. High technical flexibility and significant market adaptability. With the rapid development of the new energy vehicle industry and the expanding flat-wire motor market, the demand for plug-in systems is becoming increasingly diverse. This intelligent plug-in system can be customized to meet diverse market demands, providing flexible and diverse solutions.

[0108] 6. This system will bring significant economic and social benefits by improving production efficiency, reducing manufacturing costs and increasing yield, thereby gaining more competitive advantages in the market.

[0109] In summary, the automatic wiring system developed in this project has a significant competitive advantage in the current domestic and international market, not only can solve the technical problems in the industry, but also can provide customers with more efficient, more reliable and more flexible wiring solutions.

[0110] Currently, the wiring system is mainly applied to the manufacturing of drive motors of new energy vehicles, but can also be expanded to other motor manufacturing fields that require efficient and accurate wiring.

[0111] Finally, it should be noted that the above examples are only used to illustrate the technical solutions of the present application, and are not limited thereto; although the present application has been described in detail with reference to the foregoing examples, those skilled in the art should understand that the technical solutions described in the foregoing examples can still be modified, or some technical features can be replaced by equivalents; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. An intelligent forming and inserting system for stator flat wires, characterized by: It comprises a variable-pitch stepping feeding device, a paint removal self-detection module (50), a wire cutting module (60), a flat wire forming device, a manipulator wire insertion mechanism (130), a rotary disc single-layer wire insertion device, a split wire insertion device and a system controller, which are arranged in sequence; The variable-pitch step-by-step feeding device comprises an unwinding buffer module (10), a straightening module (20), a feeding visual inspection module (30) and a variable-length wire feeding module (40); the unwinding buffer module (10) adopts a double-material coil and a counterweight buffer mechanism to supply pre-corrected flat wire raw materials with constant tension; the straightening module (20) comprises a plurality of sets of alternately arranged horizontal straightening mechanisms (21) and vertical shaping mechanisms (22) to perform line straightening; the feeding visual inspection module (30) comprises a flat wire feeding camera and a flat wire feeding detection light source arranged on a visual inspection frame to detect whether the flat wire line shape before paint removal meets the standard; the variable-length wire feeding module (40) adopts an encoding wheel mechanism to realize the step-by-step delivery of the flat wire according to the set length; The variable pitch step feeding device can provide the flat wire raw materials after correction and visual inspection with controllable variable length steps. The paint removal self-detection module (50) uses a multi-head laser to peel the flat wire at a set position. The wire cutting module (60) cuts the flat wire at the peeling position. The flat wire forming device bends and molds the cut flat wire and detects and screens it. The manipulator wire insertion mechanism (130) picks up the formed flat wire and inserts the wire at the turntable single-layer wire insertion device to form a single-layer full-turn flat wire layer. The split wire insertion device receives the single-layer full-turn flat wire layer and completes the stator winding wiring when the sub-tray is fully inserted.

2. The intelligent forming and inserting wire system according to claim 1, characterized in that: The paint removal self-detection module (50) includes a three-link drive mechanism (51), a multi-head paint removal assembly (54) and a paint ash absorption assembly (55) arranged on a peeling frame (53); the bottom of the peeling frame (53) is mounted on the sliding top plate of the three-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; the paint removal head (541) is mounted on the paint removal adjustment assembly (542), the paint removal detection camera (543) is mounted on the paint removal head (541), and the entire multi-head paint removal module is mounted on the peeling frame (53) through the paint removal adapter.

3. The stator flat wire intelligent forming system according to claim 1, characterized in that: The cutting module (60) includes a cutting mechanism (61), a material receiving pipe (62), a material receiving box (63), a cutting controller (64) and a cutting stand (65); the cutting mechanism (61) is arranged on the top plate of the cutting stand (65), the top end of the material receiving pipe (62) is arranged at the material receiving opening on the top plate of the cutting stand (65), the lower end of the material receiving pipe (62) is arranged facing the material receiving box (63) on the bottom plate of the cutting stand (65), and the cutting controller (64) controls the cutting action of the cutting mechanism (61).

4. The stator flat wire intelligent forming system according to claim 1, characterized in that: The flat wire forming device comprises a 2D forming module (70), a 3D forming module (80), a forming visual inspection module (90), a carbon brush inspection module (100), a forming handling module (110), and a forming flat wire feeding module (120); the 2D forming module (70) adopts a bending mechanism to bend the cut flat wire segments; the 3D forming module (80) adopts a molding tower molding mechanism to realize module switching and molding of flat wires of different specifications; The forming visual inspection module (90) is used to detect whether the crown end shape of the flat wire after 3D compression molding meets the standard; the carbon brush detection module (100) is used to detect the insulation of the 3D flat wire; the forming handling module (110) adopts translation, rotation and clamping mechanisms to realize the transfer of the flat wire between different workstations; the forming flat wire unloading module (120) receives the flat wire after compression molding.

5. The stator flat wire intelligent forming system according to claim 4, characterized in that: The molding tower molding mechanism of the 3D molding module (80) includes a plurality of lower mold assemblies (81) of different models installed on the lower mold mounting plate (83), a plurality of upper mold assemblies (82) of different models installed on the upper mold mounting plate (84), a molding drive assembly (85), a sliding mounting plate (86), a lifting switching assembly (87) and a fixed back plate frame (88); the lifting switching assembly (87) drives the sliding mounting plate (86) to lift and lower the entirety to realize the switching of different types of molds in the processing position, and the molding drive assembly (85) drives the lower mold assembly (81) and the upper mold assembly (82) on the corresponding side to realize the molding 3D molding of the flat wire.

6. The stator flat wire intelligent forming system according to claim 1, characterized in that: The turntable-type single-layer wire insertion device comprises a multi-station turntable mechanism (140), a wire insertion position lifting and rotating mechanism (150), a material picking and lifting mechanism (160) and a wire insertion error prevention visual detection mechanism; the manipulator wire insertion mechanism (130) is used to clamp flat wires of different specifications and send them to the top of the wire insertion position of the multi-station turntable mechanism (140); the multi-station turntable mechanism (140) is used to rotate and provide wire insertion stations of different layers; the wire insertion position lifting and rotating mechanism (150) and the material picking and lifting mechanism (160) are arranged below the multi-station turntable mechanism (140) and are used to rotate and assist the upper wire insertion station in wire insertion or lifting to facilitate full-circle material picking; the error prevention visual detection mechanism is used to monitor the line type and position of the flat wire sending card, and realize real-time judgment and feedback of wrong insertion or missed insertion.

7. The stator flat wire intelligent forming system according to claim 6, characterized in that: The split wire insertion device comprises a transport frame (170), a transport clamp faceplate module (180), a stator wire take-up module (190) and a split wire insertion detection module (200); the transport clamp faceplate module (180) is arranged on the top of the transport frame (170) and is driven to move horizontally along the top of the frame, the stator wire take-up module (190) is arranged below the transport frame (170) and receives a full circle of single-layer flat wire pressed down by the transport clamp faceplate module (180), and the split wire insertion detection module (200) is arranged adjacent to the stator wire take-up module (190) to monitor the wire insertion status.

8. The stator flat wire intelligent forming system according to claim 7, 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 the transporting bottom plate (46) of the transporting frame (170); 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 pressure ring of the flat line lowering mechanism (186) is spatially raised and lowered and arranged between the inner support mechanism (183) and the mechanism for grabbing the lower faceplate (184).

9. The stator flat wire intelligent forming system according to claim 7, characterized in that: The stator wire-taking module (190) comprises a wire-taking frame (191), a wire-taking top plate (192), a wire diameter adjustment mechanism (193) and a hypothetical sub-tray (194); the wire-taking top plate (192) is arranged on the wire-taking frame (191), the wire diameter adjustment mechanism (193) is arranged at the middle wire-taking hole of the wire-taking top plate (192), and the hypothetical sub-tray (194) is arranged between the wire diameter adjustment mechanism (193) and the wire-taking top plate (192) for collecting a whole circle of flat wire.

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