A new energy vehicle flat wire motor coil assembling device and assembling method

Abstract

The present application relates to a kind of assembly devices, specifically to a kind of new energy automobile flat wire motor coil assembly device and assembly method.The assembly device includes rack, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack by turnover mechanism, and winding mechanism is installed on the rack

Description

Technical Field

[0001] This invention relates to an assembly device and assembly method, specifically to an assembly device and assembly method for flat wire motor coils in new energy vehicles. Background Technology

[0002] Currently, due to the widespread application of electric vehicles, the core drive unit of electric vehicles—the electric motor—has received extensive attention. An electric motor consists of a stator and a rotor. The stator comprises a stator core and coils, which are made of copper wire. To improve slot fill factor and power density, existing coils use enameled flat copper wire. The coils are installed by bending and arranging the flat copper wire and then inserting it into the slots of the stator core.

[0003] Patent application CN115940547A discloses an automatic pre-insertion and take-up mechanism and method for flat wire stators of new energy motors. The tray circulates on the production line, with a fixed station that rises and falls to support the device. An inner limiting shaft is vertically positioned at the center of the tray. A take-up and insertion device is mounted on the top of the inner limiting shaft via a pin. A limiting plate is bolted to the lower ring of the inner limiting shaft. A limiting groove is mounted on the upper part of the limiting plate via a pin. Three lifting sleeves are evenly distributed on the lower part of the limiting plate, cooperating with a lifting device on the production line to raise and lower the limiting plate and the limiting groove. This invention solves the problems of existing robotic arms being unable to automatically complete the pre-insertion and take-up of coil stators with complex multi-layer wire structures (eight layers or more), requiring manual operation, resulting in low efficiency and difficulty in guaranteeing quality.

[0004] The aforementioned pre-insertion and take-up mechanism can arrange the coil wires, but it inserts the wires vertically along the axial direction. After insertion, it does not limit the movement of the copper wires, making them prone to displacement. Furthermore, as the number of layers increases during insertion, the copper wires become denser. On one hand, the copper wires have poor resilience and are easily deformed. At the same time, the insertion process requires high precision; even slight deformation can make insertion difficult or impossible. On the other hand, the denser copper wires can scratch the enamel coating at the ends, and friction between the wires can also damage the coating, easily leading to poor insulation or even loss of insulation performance. Therefore, it is necessary to develop a flat wire motor coil assembly device and method for new energy vehicles to solve these problems. Summary of the Invention

[0005] The purpose of this invention is to provide a new energy vehicle flat wire motor coil assembly device and assembly method that can effectively reduce the assembly precision requirements of cross-layer coils in flat wire motors, thereby facilitating assembly, reducing friction and scratches between coils, and effectively protecting the paint.

[0006] The technical solution of this invention is:

[0007] A new energy vehicle flat wire motor coil assembly device comprises a frame, a flipping mechanism, a winding mechanism, a wire taking mechanism, a stator fixture, and a pressing mechanism. Its features include: a winding mechanism mounted on the frame via the flipping mechanism; a wire taking mechanism mounted on the frame at the rear end of the winding mechanism; a stator fixture movably mounted on the frame on one side of the wire taking mechanism via a slide rail; one side of the stator fixture being connected to a lead screw pair A mounted on the frame; and a pressing mechanism mounted on the frame at the front end of the stator fixture.

[0008] The flipping mechanism consists of a support plate, a flipping half gear, and a flipping motor arranged in parallel. The flipping half gear is movably mounted on the inner side of one of the support plates via a bearing, and the flipping motor is located on the outer side of the support plate. The output shaft of the flipping motor extends to the inner side of the support plate, and the output shaft of the flipping motor extending to the inner side of the support plate meshes with the flipping half gear via a gear. The support plates are movably connected to the frame via slide rails, and the support plate below the flipping motor is connected to the lead screw pair B set on the frame.

[0009] The winding mechanism consists of a winding support frame, a drum, a winding limit plate, and an indexing motor. The drum is movably mounted on the winding support frame via bearings, and winding limit plates are inserted at intervals on the drum. An indexing motor that drives the drum to rotate is provided at the tail end of the winding support frame. One side of the winding support frame is movably connected to a support plate via a short shaft, and the other side of the winding support frame is fixedly connected to a reversing half gear.

[0010] The inner side of the winding limit plate is provided with an adjustment groove, which is inclined.

[0011] The tail of the winding support frame is also equipped with an adjusting electric cylinder. The piston rod of the adjusting electric cylinder extends into the drum, and the end of the piston rod extending into the drum is equipped with an adjusting cone. The adjusting cone is movably inserted into the adjusting groove.

[0012] A copper wire limiting mechanism is installed on the frame below the reel.

[0013] The copper wire limiting mechanism consists of a slide block, a mounting base, a lifting cylinder, a fixed wheel, a swing arm, a moving wheel, and a moving cylinder. The mounting base is movably mounted on the slide block via a guide rod. A lifting cylinder is located at the bottom of the slide block, and the piston rod end of the lifting cylinder is fixedly connected to the mounting base. Fixed wheels are symmetrically arranged on the mounting base. A swing arm is mounted on the mounting base outside the fixed wheels via a connecting rod. A moving wheel is located at the top of the swing arm. A moving cylinder is located on the mounting base below the swing arm, and the piston rod end of the moving cylinder is movably connected to the swing arm via a pin. The slide block is connected to the frame via a slide rail.

[0014] The wire taking mechanism consists of a wire taking base, a wire taking electric cylinder, and a clamping limiter. The wire taking base is equipped with a wire taking electric cylinder, and the piston rod end of the wire taking electric cylinder is equipped with a clamping limiter. The wire taking base is movably connected to the frame via a slide rail, and one side of the wire taking base is connected to a lead screw pair C set on the frame.

[0015] The clamping limiter consists of an assembly base, clamping blocks, pins, a drive ring, and a clamping motor. Clamping blocks are evenly distributed and inserted onto the assembly base, forming a "7" shape. Pins are located at the top ends of the clamping blocks. A drive ring is fitted onto the assembly base above the clamping blocks, and the drive ring has evenly distributed spiral drive grooves. These drive grooves are fitted and connected to the top ends of the pins. Drive teeth are provided on the drive ring, and a clamping motor is mounted on the assembly base above the drive teeth. The output shaft of the clamping motor meshes with the drive teeth via gears. The assembly base is movably connected to the wire take-up seat via a guide rod and fixedly connected to the piston rod of the wire take-up electric cylinder.

[0016] A limit plate is provided on the inner side of the bottom end of the clamping block.

[0017] The pressing mechanism consists of a pressing bracket, a pressing electric cylinder, and a pressing plate. The pressing bracket is equipped with a pressing electric cylinder, and the piston rod end of the pressing electric cylinder is equipped with a pressing plate.

[0018] The pressing bracket below the pressure plate is equipped with a support plate for supporting the stator tooling slide rail.

[0019] The lead screw assembly A, lead screw assembly B, and lead screw assembly C respectively include a lead screw, a lead screw nut, and a lead screw motor.

[0020] A method for assembling flat wire motor coils for new energy vehicles, characterized by the following steps:

[0021] 1) Place the rubber band between the fixed wheel and the moving wheel of the copper wire limiting mechanism of the new energy vehicle flat wire motor coil assembly device; start the lifting cylinder, which drives the fixed wheel, the moving wheel and the rubber band to move upward through the mounting base. After the fixed wheel moves into position, start the moving cylinder, which drives the moving wheel through the swing arm, so that the rubber band is wrapped around the front end of the winding mechanism drum to prevent the coil from falling off.

[0022] 2) Place the coil on the winding mechanism, so that the two ends of the coil are respectively engaged between the winding limit plates of the winding mechanism. Insert the end of the coil into the winding support frame, and limit the end of the coil by the winding support frame. After one coil is engaged, the indexing motor drives the coil to rotate through the drum and the winding limit plate. After the coil rotates to the position, place the next coil, so that the bend of the next coil overlaps with the bend of the already placed coil. By stacking and using rubber bands to limit the coil, the coil is prevented from falling off during rotation.

[0023] 3) After the drum rotates one revolution, start the adjusting electric cylinder. The adjusting electric cylinder drives the adjusting cone to move forward, pushing the winding limit plate outward by the thickness of a copper wire.

[0024] 4) Repeat steps 3)-4) to wind multiple layers of copper wire onto the winding mechanism;

[0025] 5) After the winding is completed, the rubber band is opened by resetting the moving wheel and the fixed wheel; start the lead screw pair B, which drives the winding mechanism and the wound coil to move to the bottom of the take-up mechanism through the flipping mechanism;

[0026] 6) Start the flip motor. The flip motor drives the winding mechanism to rotate through the flip half gear, so that the coil is vertically upward;

[0027] 7) Start the wire-retrieving electric cylinder. The wire-retrieving electric cylinder drives the clamping limiter downward, so that the top end of the coil enters between the clamping blocks.

[0028] 8) After the clamping limiter descends to the lower position, start the clamping motor. The clamping motor pushes the clamping block inward through the drive teeth, drive ring, and pawl in sequence, so that the clamping block clamps the coil and inserts the limit plate between the coils.

[0029] 9) After the limit plate is inserted into place, start the wire take-up electric cylinder to reset upward. The wire take-up electric cylinder pulls the coil out of the winding mechanism through the clamping limit device. During the coil pull-out process, the group of stator cores with insulating paper inserted are placed into the stator fixture.

[0030] 10) Start lead screw pair C, which moves the wire taking mechanism and the coil on the wire taking mechanism upwards towards the stator fixture; start the wire taking electric cylinder, which drives the coil downwards through the clamping limiter, pre-inserting the bottom end of the coil into the slot of the stator core; after pre-insertion, the wire taking mechanism resets and disengages from the coil;

[0031] 11) Start the lead screw pair A, which will transfer the stator fixture to the pressure plate of the pressing mechanism. After the stator fixture is in place, start the pressing electric cylinder. The pressing electric cylinder will drive the pressure plate to move downward. The pressure plate will press the coil into the stator core to form the stator.

[0032] The beneficial effects of this invention are as follows:

[0033] This new energy vehicle flat wire motor coil assembly device can wind coils one by one through a winding mechanism. During the winding process, only the position of a single coil needs to be determined, allowing for accurate and convenient coil arrangement. Furthermore, the winding process involves horizontally stacking the coils, so slight deformation of the coils does not easily affect the winding process, minimizing insertion difficulties. Since the winding process involves stacking coils rather than inserting them, friction and scratches between coils are less likely, effectively protecting the coil enamel and ensuring insulation performance. After winding, the stacking of coils and the limiting position of the winding mechanism prevent coil displacement, effectively ensuring accurate coil arrangement. A wire-taking mechanism, in conjunction with a pressing mechanism, can take the coil wire and press it into the stator core, facilitating stator assembly. This solves the problem of existing insertion mechanisms requiring high precision, leading to inconvenient insertion and potential insulation issues. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the structure of the present invention;

[0035] Figure 2 yes Figure 1 Enlarged view of point A in the middle;

[0036] Figure 3 This is an isometric schematic diagram of the winding mechanism of the present invention;

[0037] Figure 4 This is a cross-sectional schematic diagram of the winding mechanism of the present invention;

[0038] Figure 5 This is a schematic diagram of the structure of the roll of the present invention;

[0039] Figure 6 This is a schematic diagram of the structure of the winding limiting plate of the present invention;

[0040] Figure 7 This is a schematic diagram of the structure of the adjusting cone of the present invention;

[0041] Figure 8 yes Figure 1 Enlarged view of point B in the middle;

[0042] Figure 9 This is a schematic diagram of the wire taking mechanism of the present invention;

[0043] Figure 10 This is a cross-sectional schematic diagram of the clamping block of the present invention;

[0044] Figure 11 This is a schematic diagram of the drive ring structure of the present invention;

[0045] Figure 12 yes Figure 1 Enlarged view of point C in the middle;

[0046] Figure 13This is a schematic diagram of the pre-insertion state of the coil of the present invention;

[0047] Figure 14 This is a schematic diagram of the pressing mechanism of the present invention.

[0048] In the diagram: 1. Frame, 2. Tilting mechanism, 3. Winding mechanism, 4. Wire take-up mechanism, 5. Stator fixture, 6. Pressing mechanism, 7. Lead screw pair A, 8. Lead screw pair B, 9. Copper wire limiting mechanism, 10. Lead screw pair C, 11. Coil, 201. Support plate, 202. Tilting half gear, 203. Tilting motor, 301. Winding support frame, 302. Drum, 303. Winding limiting plate, 304. Indexing motor, 305. Adjusting groove, 306. Adjusting electric cylinder, 307. Adjusting cone, 4 01. Wire take-up base; 402. Wire take-up electric cylinder; 403. Assembly base; 404. Clamping block; 405. Pulley pin; 406. Drive ring; 407. Clamping motor; 408. Drive groove; 409. Drive gear; 410. Limiting plate; 601. Press-fit bracket; 602. Press-fit electric cylinder; 603. Pressure plate; 604. Support plate; 901. Slide; 902. Mounting base; 903. Lifting cylinder; 904. Fixed wheel; 905. Swing arm; 906. Moving wheel; 907. Moving cylinder; 908. Connecting rod. Detailed Implementation

[0049] This new energy vehicle flat wire motor coil assembly device consists of a frame 1, a flipping mechanism 2, a winding mechanism 3, a wire taking mechanism 4, a stator fixture 5, and a pressing mechanism 6. The frame 1 is equipped with the flipping mechanism 2, on which the winding mechanism 3 is mounted for coil winding and arrangement. The flipping mechanism 2 flips the winding mechanism 3, thereby flipping the coil during the flipping process, turning the horizontally wound coil to a vertically upward position. The wire taking mechanism 4 is located on the frame 1 at the rear end of the winding mechanism 3, allowing the coil to be removed from the winding mechanism 3 and transferred. The stator fixture 5 is movably mounted on the frame 1 via a slide rail on one side of the wire taking mechanism 4, limiting and supporting the stator core, facilitating coil insertion into the stator core. One side of the stator fixture 5 is connected to a lead screw pair A7 mounted on the frame 1. A pressing mechanism 6 is provided on the frame 1 at the front end of the stator fixture 5. The function of the lead screw pair A7 is to transfer the stator fixture 5 through the lead screw pair A7, and then push the stator iron core in the stator fixture 5 to move towards the pressing mechanism 6 after receiving the coil. The pressing mechanism 6 then presses the coil into the stator iron core, thus completing the assembly of the stator.

[0050] The flipping mechanism consists of a support plate 201, a flipping half gear 202, and a flipping motor 203 arranged in parallel. The flipping half gear 202 is movably mounted on the inner side of one of the support plates 201 via bearings, while the flipping motor 203 is located on the outer side of the support plate 201. The output shaft of the flipping motor 203 extends to the inner side of the support plate 201 and meshes with the flipping half gear 202 via gears. The support plates 201 are movably connected to the frame 1 via slide rails. The support plate 201 below the flipping motor 203 is connected to a lead screw pair B8 mounted on the frame 1. The function of the flipping motor 203 is to drive the flipping half gear 202 to rotate, thereby causing the winding mechanism 3 to flip, turning the coil wound on the winding mechanism 3 from a horizontal to a vertical position. The function of lead screw pair B8 is to drive support plate 201 to slide on slide rail, and then drive winding mechanism 3 to move through flip half gear 202 during the sliding process of support plate 201, so that winding mechanism 3 can drive the coil that has been wound to the bottom of take-up mechanism 4.

[0051] The winding mechanism 3 consists of a winding support frame 301, a winding drum 302, a winding limit plate 303, and an indexing motor 304. The winding drum 302 is movably mounted on the winding support frame 301 via bearings. The winding limit plates 303 are inserted at intervals on the winding drum 302 so that the end of the coil is limited by the winding limit plates 303 after the coil is inserted between the intervals. The tail end of the winding support frame 301 is equipped with an indexing motor 304 that drives the winding drum 302 to rotate. The indexing motor 304 drives the winding drum 302 to rotate, which in turn drives the winding limiting plate 303 to rotate. This causes the winding limiting plate 303 to rotate the coil downwards, thereby removing the wound coil from its placement position and facilitating the placement of the coil from the top of the winding drum 302. This facilitates coil winding. Furthermore, the indexing rotation allows the repositioned coil to stack on top of the previous coil, limiting the position of the previous coil. Since the coil is placed between the winding limiting plates 303, the placement position of the coil is determined by the winding limiting plates 303, ensuring accurate coil arrangement. One side of the winding support frame 301 is movably connected to the support plate 201 via a short shaft, and the other side of the winding support frame 301 is fixedly connected to the flip half gear 202.

[0052] An adjusting groove 305 is provided on the inner side of the winding limit plate 303, and the adjusting groove 305 is inclined. An adjusting electric cylinder 306 is also provided at the tail of the winding support frame 301. The piston rod of the adjusting electric cylinder 306 extends into the drum 302, and an adjusting cone 307 is provided at the end of the piston rod extending into the drum 302. The adjusting cone 307 is movably inserted into the adjusting groove 305. The function of the adjusting electric cylinder 306 is to control the forward and backward position of the adjusting cone 307, thereby adjusting the position of the winding limit plate 303 by the adjusting cone 307 in conjunction with the adjusting groove 305. During the forward movement of the adjusting cone 307, the adjusting cone 307 pushes the winding limit plate 303 outward from the drum 302 through the adjusting groove 305, thereby enabling the winding limit plate 303 to gradually extend. This ensures that the gap depth between the winding limit plates 303 is sufficient to limit the coil but not too large, reducing the resistance to inserting the coil on one hand and allowing the coil to be tightly arranged on the other. During the backward movement of the adjusting cone 307, the adjusting cone 307 drives the winding limit plate 303 inward from the drum 302 through the adjusting groove 305, causing the winding limit plate 303 to reset.

[0053] A copper wire limiting mechanism 9 is installed on the frame 1 below the drum 302 to further limit the coil and prevent the coil from falling off the winding mechanism 3 during the winding process. The copper wire limiting mechanism 9 consists of a slide 901, a mounting base 902, a lifting cylinder 903, a fixed wheel 904, a swing arm 905, a moving wheel 906, and a moving cylinder 907. The mounting base 902 is movably mounted on the slide 901 via a guide rod. The lifting cylinder 903 is located at the bottom of the slide 901, and the piston rod end of the lifting cylinder 903 is fixedly connected to the mounting base 902. Fixed wheels 904 are symmetrically arranged on the mounting base 902. A swing arm 905 is mounted on the mounting base 902 outside the fixed wheel 904 via a connecting rod 908. A moving wheel 906 is located at the top of the swing arm 905. A moving cylinder 907 is located on the mounting base 902 below the swing arm 905, and the piston rod end of the moving cylinder 907 is movably connected to the swing arm 905 via a pin. The slide 901 is connected to the frame 1 via a slide rail. The function of the fixed wheel 904 is to work with the moving wheel 906 to encircle the rubber band around the drum 302, thereby further limiting the coil's position. The overlapping of the rubber bands also helps to mutually limit the coil's movement, ensuring it doesn't easily fall off during winding. The lifting cylinder 903 moves the mounting base 902 up and down, which in turn moves the fixed wheel 904 up and down, allowing it to reach the bottom of the drum 302. The fixed wheel 904, in conjunction with the rubber band, then supports the coil at the bottom of the drum 302. The moving cylinder 907 moves the swing arm 905, which in turn moves the moving wheel 906. This allows the moving wheel 906 to retract the rubber band towards the drum 302, thus limiting the coil's position; or it can cause the moving wheel 906 to open the rubber band, preventing it from interfering with the coil's movement after winding.

[0054] The wire taking mechanism 4 consists of a wire taking seat 401, a wire taking electric cylinder 402, and a clamping limiter. The wire taking seat 401 is equipped with the wire taking electric cylinder 402, and the piston rod end of the wire taking electric cylinder 402 is equipped with a clamping limiter to clamp and limit the coil. The wire taking seat 401 is movably connected to the frame 1 via a slide rail, and one side of the wire taking seat 401 is connected to a lead screw pair C10 mounted on the frame 1. The function of the wire taking electric cylinder 402 is to pull the clamping limiter after the coil is clamped by the clamping limiter, thereby pulling the coil and removing it from the winding mechanism. The function of the lead screw pair C10 is to drive the wire taking seat 401 to move, which in turn drives the coil to move via the clamping limiter, transferring the coil from the winding mechanism 3 to the pressing mechanism 6.

[0055] The clamping limiter consists of a mounting base 403, clamping blocks 404, a pin 405, a drive ring 406, and a clamping motor 407. Clamping blocks 404 are evenly distributed and inserted into the mounting base 403, each clamping block 404 being in the shape of a "7". A pin 405 is located at the top end of each clamping block 404. A drive ring 406 is fitted onto the mounting base 403 above the clamping blocks 404. Spiral drive grooves 408 are evenly distributed on the drive ring 406, and these drive grooves are fitted into the top end of the pin 405. Drive teeth 409 are located on the drive ring 406. The clamping motor 407 is located on the mounting base 403 above the drive teeth 409, and the output shaft of the clamping motor 407 meshes with the drive teeth 409 via gears. The mounting base 403 is movably connected to the wire take-up base 401 via a guide rod and is fixedly connected to the piston rod of the wire take-up electric cylinder 402. The function of the clamping motor 407 is to drive the gear to rotate, which in turn drives the drive ring 406 to rotate through the gear and drive teeth 409. The drive ring 406 then pushes the clamping block 404 to move through the pin 405, thereby clamping and fixing the coil through the clamping block 404.

[0056] A limiting plate 410 is provided on the inner side of the bottom end of the clamping block 404 so that it can be inserted between the coils, thereby limiting the wire taking mechanism 4 from taking the wire and preventing the coil from shifting during the coil transfer process.

[0057] The pressing mechanism 6 consists of a pressing bracket 601, a pressing electric cylinder 602, and a pressing plate 603. The pressing electric cylinder 602 is mounted on the pressing bracket 601, and the pressing plate 603 is mounted on the piston rod end of the pressing electric cylinder 602. The function of the pressing electric cylinder 602 is to drive the pressing plate 603 to rise and fall, and then, during the downward movement of the pressing plate 603 driven by the pressing electric cylinder 602, the coil is pressed down by the pressing plate 603, thereby pressing the coil 603 into the stator core.

[0058] The pressing bracket 601 below the pressing plate 603 is provided with a support plate 604 for supporting the slide rail of the stator tooling 5. The support plate 604 supports the slide rail, and thus, during the pressing process of the coil by the pressing plate 603, the support of the support plate 604 overcomes the force exerted on the slide rail by the coil, stator core and stator tooling 5 in sequence by the pressing plate, thereby preventing the slide rail from deforming.

[0059] Screw assembly A7, screw assembly B8, and screw assembly C10 each include a screw, a screw nut, and a screw motor, respectively.

[0060] The assembly method for the flat wire motor coil of this new energy vehicle includes the following steps:

[0061] 1) Place the rubber band between the fixed wheel 904 and the moving wheel 906 of the copper wire limiting mechanism 9 of the new energy vehicle flat wire motor coil assembly device; start the lifting cylinder 903, which drives the fixed wheel 904, the moving wheel 906 and the rubber band to move upward through the mounting base 902 respectively. After the fixed wheel 904 moves to the position, start the moving cylinder 907, which drives the moving wheel 906 to move through the swing arm 905, so that the rubber band is wrapped around the front end of the drum 302 of the winding mechanism 3 to prevent the coil from falling off.

[0062] 2) Place the coil on the winding mechanism 3, so that the two ends of the coil are respectively engaged between the winding limit plates 303 of the winding mechanism 3. Insert the end of the coil into the winding support frame 301, and limit the end of the coil through the winding support frame 301. After one coil is engaged, the indexing motor 304 drives the coil to rotate through the drum 302 and the winding limit plate 303. After the coil rotates to the position, place the next coil, so that the bend of the next coil overlaps with the bend of the already placed coil. By stacking and using rubber bands to limit the coil, the coil is prevented from falling off during rotation.

[0063] 3) After the drum 302 rotates one revolution, start the adjusting electric cylinder 306. The adjusting electric cylinder 306 drives the adjusting cone 307 to move forward, pushing the winding limit plate 303 outward by the thickness of a copper wire.

[0064] 4) Repeat steps 3)-4) to wind multiple layers of copper wire onto winding mechanism 3;

[0065] 5) After the winding is completed, the moving wheel 906 and the fixed wheel 904 are reset to open the rubber band; start the lead screw pair B8, and the lead screw pair B8 drives the winding mechanism 3 and the wound coil to move to the bottom of the take-up mechanism 4 through the flipping mechanism 2;

[0066] 6) Start the flip motor 203. The flip motor 203 drives the winding mechanism 3 to rotate through the flip half gear 202, so that the coil is vertically upward;

[0067] 7) Start the wire-taking electric cylinder 402. The wire-taking electric cylinder 402 drives the clamping limiter downward, so that the top end of the coil enters between the clamping blocks 404.

[0068] 8) After the clamping limiter descends to the lower position, start the clamping motor 407. The clamping motor 407 pushes the clamping block 404 inward through the drive tooth 409, drive ring 406, and deflector 405 in sequence, so that the clamping block 404 clamps the coil and inserts the limit plate 410 between the coils.

[0069] 9) After the limit plate 410 is inserted into place, the wire take-up electric cylinder 402 is started to reset upward. The wire take-up electric cylinder 402 pulls the coil out of the winding mechanism 3 through the clamping limiter. During the coil pull-out process, the group of stator cores with insulating paper inserted are placed into the stator fixture 5.

[0070] 10) Start the lead screw pair C10, which moves the wire taking mechanism 4 and the coil on the wire taking mechanism 4 upwards towards the stator fixture 5; start the wire taking electric cylinder 402, which drives the coil downwards through the clamping limiter, and pre-inserts the bottom end of the coil into the slot of the stator core; after pre-insertion, the wire taking mechanism 4 resets and disengages from the coil;

[0071] 11) Start the lead screw pair A7. The lead screw pair A7 transfers the stator fixture 5 to the pressure plate 603 of the pressing mechanism 6. After the stator fixture 5 is transferred to the position, start the pressing electric cylinder 602. The pressing electric cylinder 602 drives the pressure plate 603 to move downward. The pressure plate 603 squeezes the coil and presses the coil into the stator core to form the stator.

[0072] This new energy vehicle flat wire motor coil assembly device can wind coils one by one through a winding mechanism. During the winding process, only the position of a single coil needs to be determined, allowing for accurate and convenient coil arrangement. Furthermore, the winding process involves horizontally stacking the coils, so slight deformation of the coils does not easily affect the winding process, minimizing insertion difficulties. Since the winding process involves stacking coils rather than inserting them, friction and scratches between coils are less likely, effectively protecting the coil enamel and ensuring insulation performance. After winding, the stacking of coils and the limiting position of the winding mechanism prevent coil displacement, effectively ensuring accurate coil arrangement. A wire-taking mechanism, in conjunction with a pressing mechanism, can take the coil wire and press it into the stator core, facilitating stator assembly. This solves the problem of existing insertion mechanisms requiring high precision, leading to inconvenient insertion and potential insulation issues.

Claims

1. A new energy vehicle flat wire motor coil assembly device, comprising a frame (1), a flipping mechanism (2), a winding mechanism (3), a wire taking mechanism (4), a stator fixture (5), and a pressing mechanism (6), characterized in that: A winding mechanism (3) is installed on the frame (1) via a flipping mechanism (2). A wire taking mechanism (4) is provided on the frame (1) at the rear end of the winding mechanism (3). A stator fixture (5) is movably installed on the frame (1) on one side of the wire taking mechanism (4) via a slide rail. One side of the stator fixture (5) is connected to a lead screw pair A (7) provided on the frame (1). A pressing mechanism (6) is provided on the frame (1) at the front end of the stator fixture (5). The winding mechanism (3) consists of a winding support frame (301), a winding drum (302), a winding limit plate (303), and an indexing motor (304). The winding support frame (301) is movably mounted on the winding drum (302) via bearings. The winding limit plates (303) are inserted at intervals on the winding drum (302). The tail end of the winding support frame (301) is provided with an indexing motor (304) that drives the winding drum (302) to rotate. One side of the winding support frame (301) is movably connected to the support plate (201) via a short shaft, and the other side of the winding support frame (301) is fixedly connected to the reversing half gear (202). The inner side of the winding limit plate (303) is provided with an adjustment groove (305), and the adjustment groove (305) is inclined. The tail of the winding support frame (301) is also provided with an adjusting electric cylinder (306). The piston rod of the adjusting electric cylinder (306) extends into the drum (302). The end of the piston rod of the adjusting electric cylinder (306) extending into the drum (302) is provided with an adjusting cone (307). The adjusting cone (307) is movably inserted into the adjusting groove (305). A copper wire limiting mechanism (9) is installed on the frame (1) below the drum (302); The copper wire limiting mechanism (9) consists of a slide (901), a mounting base (902), a lifting cylinder (903), a fixed wheel (904), a swing arm (905), a moving wheel (906), and a moving cylinder (907). The mounting base (902) is movably mounted on the slide (901) via a guide rod. The lifting cylinder (903) is located at the bottom of the slide (901), and the piston rod end of the lifting cylinder (903) is fixedly connected to the mounting base (902). A fixed wheel (904) is symmetrically arranged on the upper part. A swing arm (905) is mounted on the mounting seat (902) on the outer side of the fixed wheel (904) via a connecting rod (908). A moving wheel (906) is arranged on the top of the swing arm (905). A moving cylinder (907) is arranged on the mounting seat (902) below the swing arm (905). The piston rod end of the moving cylinder (907) is movably connected to the swing arm (905) via a pin. The slide (901) is connected to the frame (1) via a slide rail.

2. The new energy vehicle flat wire motor coil assembly device according to claim 1, characterized in that: The flipping mechanism consists of a support plate (201), a flipping half gear (202), and a flipping motor (203) arranged in parallel. The flipping half gear (202) is movably mounted on the inner side of one of the support plates (201) via a bearing. The flipping motor (203) is arranged on the outer side of the support plate (201). The output shaft of the flipping motor (203) extends to the inner side of the support plate (201). The output shaft of the flipping motor (203) extending to the inner side of the support plate (201) meshes with the flipping half gear (202) via a gear. The support plates (201) are movably connected to the frame (1) via slide rails. The support plate (201) below the flipping motor (203) is connected to the lead screw pair B (8) arranged on the frame (1).

3. The new energy vehicle flat wire motor coil assembly device according to claim 1, characterized in that: The wire taking mechanism (4) consists of a wire taking seat (401), a wire taking electric cylinder (402), and a clamping limiter. The wire taking seat (401) is equipped with a wire taking electric cylinder (402), and the piston rod end of the wire taking electric cylinder (402) is equipped with a clamping limiter. The wire taking seat (401) is movably connected to the frame (1) through a slide rail, and one side of the wire taking seat (401) is connected to the lead screw pair C (10) set on the frame (1).

4. The new energy vehicle flat wire motor coil assembly device according to claim 3, characterized in that: The clamping limiter consists of a mounting base (403), clamping blocks (404), a pin (405), a drive ring (406), and a clamping motor (407). Clamping blocks (404) are evenly distributed and inserted onto the mounting base (403). The clamping blocks (404) are shaped like the number "7," and a pin (405) is provided at the top end of each clamping block (404). A drive ring (406) is fitted onto the mounting base (403) above the clamping blocks (404). The drive ring (406) has evenly distributed spiral drive grooves (408). The top end of the pin (405) is connected to the drive ring (406); a drive tooth (409) is provided on the drive ring (406); a clamping motor (407) is provided on the mounting base (403) above the drive tooth (409); the output shaft of the clamping motor (407) meshes with the drive tooth (409) through a gear; the mounting base (403) is movably connected to the wire take-up base (401) through a guide rod and is fixedly connected to the piston rod of the wire take-up electric cylinder (402); a limit plate (410) is provided on the inner side of the bottom end of the clamping block (404).

5. The assembly device for a flat wire motor coil of a new energy vehicle according to claim 1, characterized in that: The pressing mechanism (6) consists of a pressing bracket (601), a pressing electric cylinder (602), and a pressing plate (603). The pressing bracket (601) is equipped with a pressing electric cylinder (602), and the piston rod end of the pressing electric cylinder (602) is equipped with a pressing plate (603). A support plate (604) is provided on the pressing bracket (601) below the pressure plate (603). The support plate (604) is abutted against the slide rail of the stator fixture (5) so as to support the slide rail through the support plate (604) to overcome the downward pressure on the stator fixture (5) and the slide rail during coil assembly and prevent the slide rail from deforming.

6. The assembly method of a flat wire motor coil assembly device for new energy vehicles according to any one of claims 1-5, characterized in that: Includes the following steps: 1) Place the rubber band between the fixed wheel (904) and the moving wheel (906) of the copper wire limiting mechanism (9) of the new energy vehicle flat wire motor coil assembly device; start the lifting cylinder (903), the lifting cylinder (903) drives the fixed wheel (904), the moving wheel (906) and the rubber band to move upward through the mounting base (902). After the fixed wheel (904) moves to the position, start the moving cylinder (907), the moving cylinder (907) drives the moving wheel (906) to move through the swing arm (905), so that the rubber band is wrapped around the front end of the drum (302) of the winding mechanism (3) to prevent the coil from falling off; 2) Place the coil on the winding mechanism (3) so that the two ends of the coil are respectively engaged between the winding limit plates (303) of the winding mechanism (3). Insert the end of the coil into the winding support frame (301) and limit the end of the coil through the winding support frame (301). After one coil is engaged, the indexing motor (304) drives the coil to rotate through the drum (302) and the winding limit plate (303). After the coil rotates to the position, place the next coil so that the bend of the next coil overlaps with the bend of the coil that has been placed. By stacking and using rubber bands to limit the coil, the coil is prevented from falling off during rotation. 3) After the drum (302) rotates one revolution, start the adjusting electric cylinder (306). The adjusting electric cylinder (306) drives the adjusting cone (307) to move forward, pushing the winding limit plate (303) outward by the thickness of a copper wire. 4) Repeat steps 2)-3) to wind the multilayer copper wire onto the winding mechanism (3); 5) After the winding is completed, the rubber band is opened by resetting the moving wheel (906) and the fixed wheel (904); start the lead screw pair B (8), and the lead screw pair B (8) drives the winding mechanism (3) and the wound coil to move to the bottom of the wire taking mechanism (4) through the flipping mechanism (2); 6) Start the flip motor (203). The flip motor (203) drives the winding mechanism (3) to rotate through the flip half gear (202), so that the coil is vertically upward; 7) Start the wire-taking electric cylinder (402). The wire-taking electric cylinder (402) drives the clamping limiter to move downward, so that the top end of the coil enters between the clamping blocks (404); 8) After the clamping limiter descends to the position, start the clamping motor (407). The clamping motor (407) pushes the clamping block (404) inward through the drive teeth (409), drive ring (406), and pin (405) in sequence, so that the clamping block (404) clamps the coil and inserts the limit plate (410) between the coils. 9) After the limit plate (410) is inserted into place, start the wire take-up electric cylinder (402) to reset upward. The wire take-up electric cylinder (402) pulls the coil out of the winding mechanism (3) through the clamping limit device. During the coil pull-out process, the stator iron core with the insulating paper inserted is put into the stator fixture (5). 10) Start the lead screw pair C (10), the lead screw pair C (10) moves the wire taking mechanism (4) and the coil on the wire taking mechanism (4) to the stator fixture (5) above; start the wire taking electric cylinder (402), the wire taking electric cylinder (402) drives the coil down through the clamping limiter, and pre-inserts the bottom end of the coil into the slot of the stator iron core; after pre-insertion, the wire taking mechanism (4) resets and disengages from the coil; 11) Start the lead screw pair A (7), the lead screw pair A (7) transfers the stator fixture (5) to the pressure plate (603) of the pressing mechanism (6); after the stator fixture (5) is transferred to the position, start the pressing electric cylinder (602), the pressing electric cylinder (602) drives the pressure plate (603) to move down, and the pressure plate (603) squeezes the coil to press the coil into the stator core to form the stator.

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