Stator winding method and stator winding production line

Abstract

The application discloses a stator winding method and a stator winding production line, and relates to the technical field of motor manufacturing, wherein the stator winding method is applied to the stator winding production line; the stator winding production line comprises a bending machine, a winding machine and a straightening machine; the stator winding method comprises the following steps: feeding a strip-shaped stator core to the bending machine, and controlling the bending machine to bend the strip-shaped stator core to form a ring-shaped stator core with winding portions outward; controlling the winding machine to wind from the winding portions on the outer circumferential side of the ring-shaped stator core to form a ring-shaped stator; and controlling the straightening machine to expand and straighten the ring-shaped stator to form a strip-shaped stator; the application can reduce the floor area occupied by the stator winding equipment, effectively reduce the winding difficulty of the motor stator, and improve the winding quality.

Description

Technical Field

[0001] This invention relates to the field of motor manufacturing technology, and in particular to a stator winding method and a stator winding production line. Background Technology

[0002] Existing motor stator cores are generally formed by winding. Before winding, the stator core is mostly circular. However, winding on a circular stator core presents problems such as high winding difficulty, long winding time, low slot fill factor, large copper wire waste, and low production efficiency. Therefore, winding on a strip stator core is adopted. Although winding on a straight stator core slot shape reduces the difficulty and improves production efficiency, existing straight stator winding equipment occupies a large area, and the quality of the stator winding after winding is relatively low. Summary of the Invention

[0003] The main objective of this invention is to propose a stator winding method and a stator winding production line, which aims to improve winding quality while reducing the floor space occupied by stator winding equipment.

[0004] To achieve the above objectives, the stator winding method proposed in this invention is applied to a stator winding production line, which includes a bending machine, a winding machine, and a straightening machine. The stator winding method includes the following steps:

[0005] The bar stator core is fed to the bending machine, and the bending machine is controlled to bend the bar stator core into an annular stator core with the winding part facing outward.

[0006] The winding machine is controlled to wind the wire from the winding section on the outer periphery of the annular stator core to form an annular stator;

[0007] The straightening machine is controlled to unfold and straighten the annular stator to form a strip stator.

[0008] In one embodiment, the bending machine includes a bending device, which includes a bending component and a bending drive mechanism. The bending component has a strip-shaped state and an annular state. The bending drive mechanism is used to drive the bending component to switch between the strip-shaped state and the annular state. The steps of feeding the strip stator core to the bending machine and controlling the bending machine to bend the strip stator core into an annular stator core with the winding portion facing outward include:

[0009] The bending drive mechanism is controlled to drive the bending component to a strip state, and the strip stator core is positioned on the bending component in the strip state. The bending drive mechanism is controlled to drive the bending component to bend and deform, so as to switch the bending component from the strip state to the ring state, and bend the strip stator core to form a ring stator core with the winding part facing outward.

[0010] In one embodiment, the bending machine further includes a mold-feeding device. Before the step of controlling the winding machine to wind the winding portion on the outer periphery of the annular stator core to form an annular stator, the method further includes: controlling the mold-feeding device to install a mold onto the annular stator core, shaping the annular stator core, and maintaining the annular stator core in the bent annular state.

[0011] In one embodiment, the straightening machine includes a straightening device, the straightening device including a first straightening component and a second straightening component, and the step of controlling the straightening machine to unfold and straighten the annular stator to form a strip stator includes:

[0012] The first straightening assembly is controlled to unfold the annular stator into a strip stator;

[0013] The second straightening assembly is controlled to straighten the unfolded strip stator by maintaining pressure.

[0014] In one embodiment, the straightening machine further includes a demolding device, and before the step of controlling the straightening machine to unfold and straighten the annular stator to form a strip stator, the demolding device is further used to separate the annular stator from the mold.

[0015] In one embodiment, the winding machine includes a winding limiting device and a winding device. The step of controlling the winding machine to wind the winding portion on the outer periphery of the annular stator core to form an annular stator includes:

[0016] The annular stator core is positioned within the winding limiting device;

[0017] The winding device is controlled to wind the winding section on the outer periphery of the annular stator core, and the winding limiting device is controlled to drive the annular stator core to rotate axially, so that multiple winding sections on the outer periphery of the annular stator core sequentially face the winding device to complete the winding, thereby obtaining an annular stator.

[0018] The present invention also proposes a stator winding production line, comprising:

[0019] A bending machine, used to bend a strip stator core into an annular stator core with the winding portion facing outward;

[0020] A winding machine, the winding machine being used to receive annular stator cores and to wind wires onto the annular stator cores to form an annular stator; and

[0021] A straightening machine is used to unfold and straighten annular stators to form strip stators.

[0022] In one embodiment, the bending machine includes a bending device, which includes a bending component and a bending drive mechanism. The bending component has a strip-shaped state and an annular state. The bending drive mechanism is used to drive the bending component to switch between the strip-shaped state and the annular state. The bending component is used to position the strip-shaped stator core in the strip-shaped state and to bend the strip-shaped stator core in the reverse direction to form an annular stator core with the winding portion facing outward during the process of switching from the strip-shaped state to the annular state.

[0023] In one embodiment, the bending drive mechanism includes a bending drive component and two swing arms. The two swing arms are movably connected to both ends of the bending component, and the ends of the two swing arms away from the bending component are respectively connected to the bending drive component. The bending drive component is used to drive the two swing arms to expand or close relative to each other, so as to drive the bending component to switch between a strip state and a ring state.

[0024] In one embodiment, the bending device further includes a first positioning member and a second positioning member disposed opposite to each other along a first direction. The bending member is used to fit against the side of the first positioning member facing the second positioning member when it is in a strip-shaped state, and to fit against the outer surface of the second positioning member when it is in a ring-shaped state.

[0025] In one embodiment, the bending drive mechanism further includes a transmission plate movably disposed along a first direction, with the ends of the two swing arms away from the bending member respectively hinged to the transmission plate, and the bending drive member is used to drive the transmission plate to move along the first direction so as to drive the two swing arms to spread out or move closer to each other.

[0026] In one embodiment, the bending device further includes a positioning component, the positioning component including a first gripper, the first gripper being used to clamp both ends of the bending member when the bending member is in an annular state, and to bring the two ends of the bending member closer to each other, so that the bending member fits against the peripheral side surface of the second positioning member.

[0027] In one embodiment, the positioning component further includes a second gripper for gripping the beginning and end ends of the annular stator core when the bent circular piece is in an annular state, and for bringing the beginning and end ends of the annular stator core closer to each other.

[0028] In one embodiment, the bending member includes a plurality of chain links connected in sequence, each chain link having a receiving groove, and the plurality of receiving grooves being connected in sequence to form a limiting groove, the limiting groove being used to limit the placement of the annular stator core.

[0029] In one embodiment, the bending machine further includes a mold-feeding device, which includes a first clamping member, a second clamping member, and a transfer table. The first clamping member is used to clamp the mold and move the mold to the transfer table. The second clamping member is used to clamp the annular stator core and install the annular stator core onto the mold to shape the annular stator core.

[0030] In one embodiment, the second clamping member includes a rounding drive, a second base, and a plurality of third jaws. The plurality of third jaws are movably disposed on the second base and are used to clamp the outer periphery of the annular stator core. The rounding drive is used to drive the plurality of third jaws to move synchronously along the second base to round the annular stator core.

[0031] In one embodiment, the second clamping member further includes a movable plate, which is rotatably mounted on the second base along the axial direction of the second base. The movable plate has a plurality of adjustment slots spaced apart along the circumference of the second base. Each adjustment slot has a first end near the axis of the second base and a second end away from the axis of the second base. The plurality of adjustment slots are paired with a plurality of third grippers. Each third gripper has a linkage portion movably disposed in the corresponding adjustment slot. The full-circle driving member is used to drive the movable plate to rotate axially, so as to drive the linkage portion of each third gripper to reciprocate between the first end and the second end, thereby causing each third gripper to swing along the second base.

[0032] In one embodiment, the straightening machine includes a demolding device and a straightening device. The demolding device is used to receive an annular stator with the mold and to separate the annular stator from the mold. The straightening device is used to unfold the demolded annular stator to form the strip stator.

[0033] In one embodiment, the straightening device includes a first straightening component and a second straightening component. The first straightening component is used to unfold the annular stator to form a strip stator, and the second straightening component is used to hold pressure on the strip stator to straighten the strip stator.

[0034] In one embodiment, the winding machine includes a winding limiting device and a winding device. The winding limiting device is used to limit the placement of the annular stator core and to drive the annular stator core to rotate axially. The winding device is used to wind wire on the winding portion outside the annular stator core to form an annular stator.

[0035] The technical solution of this invention controls a bending machine to bend a strip stator core into an annular stator core with the winding section facing outwards. This results in a larger distance between the unconnected parts on the outer side of adjacent stator core segments. When the winding machine winds the wire from the winding section on the outer side of the annular stator core, the distance between the coil and the core can be accurately controlled, making the wire arrangement more neat and the coil shape closer to an ideal trapezoid. This improves the slot fill factor and reduces the stress on the enameled wire. Furthermore, when winding the annular stator core from the winding section to form an annular stator, a single-head winding machine can be used in conjunction with the rotation of the annular stator core, reducing the space occupied by the winding machine and thus reducing the floor space of the stator winding equipment. By controlling a straightening machine to unfold and straighten the annular stator to form a strip stator, the winding difficulty of the motor stator can be effectively reduced, the winding quality can be improved, and the floor space of the stator winding equipment can be reduced. Attached Figure Description

[0036] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0037] Figure 1 A flowchart of an embodiment of the stator winding method provided by the present invention;

[0038] Figure 2 This is a schematic diagram of the structure of an embodiment of the stator winding production line provided by the present invention;

[0039] Figure 3 for Figure 2 A schematic diagram of the structure of an embodiment of a bending machine;

[0040] Figure 4 for Figure 3 A schematic diagram of an embodiment of the bending circular device;

[0041] Figure 5 for Figure 4 A magnified view of a portion at point A;

[0042] Figure 6 for Figure 4 A schematic diagram of the structure of one embodiment of the positioning component;

[0043] Figure 7 for Figure 4 A schematic diagram of the structure of the medium-bending circular device from another angle;

[0044] Figure 8 for Figure 3A schematic diagram of the structure of an embodiment of the mold insertion device;

[0045] Figure 9 for Figure 8 A schematic diagram of the structure of one embodiment of the second clamping member;

[0046] Figure 10 for Figure 2 A schematic diagram of the structure of an embodiment of a winding machine;

[0047] Figure 11 for Figure 10 A schematic diagram of an embodiment of the winding limit device;

[0048] Figure 12 for Figure 11 A schematic diagram of the structure of an embodiment of the middle limiting fitting component;

[0049] Figure 13 for Figure 12 A schematic diagram of the structure of an embodiment of the middle limiting stage;

[0050] Figure 14 for Figure 2 A schematic diagram of the structure of an embodiment of a straightening machine;

[0051] Figure 15 for Figure 14 A schematic diagram of the structure of one embodiment of the first straightening component;

[0052] Figure 16 for Figure 15 A magnified view of the area at point B;

[0053] Figure 17 This is a schematic diagram of an embodiment of the annular stator core provided by the present invention.

[0054] Explanation of icon numbers:

[0055] 100. Stator winding production line;

[0056] 10. Bending machine; 11. Bending device; 111. First base; 112. Bending component; 112a. Limiting groove; 1121. Chain link; 1122. Positioning rod; 113. First positioning component; 114. Second positioning component; 115. Bending drive mechanism; 1151. Bending drive component; 1152. Swing arm; 1152a. Rotating part; 1153. Transmission plate; 116. Positioning assembly; 1161. First gripper; 116 1a. Positioning groove; 1162. Second gripper; 1163. Second positioning drive; 1164. First positioning drive; 12. Mold entry device; 121. Mold entry track; 122. First clamping member; 123. Second clamping member; 1231. Rounding drive; 1232. Second base; 1233. Third gripper; 1233a. Linkage part; 1234. Movable plate; 1234a. Adjustment groove; 124. Transfer platform;

[0057] 20. Winding machine; 21. Winding limiting device; 211. Placement assembly; 2111. Winding table; 2112. First rotary drive component; 212. Limiting engagement assembly; 2121. Third base; 2122. Limiting platform; 21221. Base; 21222. First limiting part; 21223. Second limiting part; 2123. First moving drive component; 213. Second moving drive component; 22. Winding device; 23. Loading and unloading device;

[0058] 30. Straightening machine; 31. Straightening device; 311. First straightening assembly; 3111. Roller; 3112. First straightening drive component; 3113. Straightening mounting component; 312. Second straightening assembly; 3121. Pressure plate; 3122. Pressure column; 32. Demolding device; 321. Placement assembly; 322. Demolding assembly; 33. Workbench; 34. Positioning plate;

[0059] 40. Transfer device;

[0060] 1. Annular stator core; 1a. Sub-stator core.

[0061] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0062] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0063] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back, etc.), the directional indications are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indications will also change accordingly.

[0064] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0065] Currently, most motor stator cores are generally formed by winding. Before winding, the stator core is mostly circular. However, winding on a circular stator core presents problems such as high winding difficulty, long winding time, low slot fill factor, large copper wire waste, and low production efficiency. Therefore, winding on a strip stator core is adopted. Although winding on a straight strip stator core slot shape reduces the difficulty and improves production efficiency, after winding, the stator needs to be pre-treated and then bent into a circle. The coil and cross wire completed in the straight state are bent into a circle. Due to tension and deformation, the distance between the coil and the core and the wire diameter change, resulting in some defective products.

[0066] Meanwhile, the factory's existing straight stator winding equipment occupies a large area, and each production line requires multiple winding machines; the equipment's winding process is poor, resulting in low slot fill rate and enameled wire defects (broken wire, thinned wire diameter, damage), leading to scrapping due to poor turn-to-turn quality and poor withstand voltage. This not only wastes a large amount of raw materials (copper wire, aluminum wire, BMC stator) but also wastes production time, reducing the factory's production efficiency and profitability.

[0067] This invention proposes a stator winding method, which is applied to a stator winding production line 100, the stator winding production line including a bending machine 10, a winding machine 20 and a straightening machine 30.

[0068] Please see Figure 1 In one embodiment of the present invention, the stator winding method includes the following steps:

[0069] S100: Feed the bar stator core to the bending machine 10, and control the bending machine 10 to bend the bar stator core into an annular stator core 1 with the winding part facing outward;

[0070] S200: Control the winding machine 20 to wind the winding part on the outer periphery of the annular stator core 1 to form an annular stator;

[0071] S300: Control the straightening machine 30 to unfold and straighten the annular stator to form a strip stator.

[0072] In this invention, the stator core includes a plurality of sequentially connected sub-stator cores. Adjacent sub-stator core segments are connected on one side to form a connecting portion, while the other side of two adjacent sub-stator core segments is not connected to form a winding portion with an insertion port. Each sub-stator core has a winding slot for winding the coil. During stator winding, enameled wire can be inserted through the winding portion and wound in the winding slot.

[0073] The bending machine 10 may include a bending device 11 for bending a strip stator core into an annular stator core with the winding portion facing outwards. The bending device 11 may include a bending component and a bending drive mechanism. It employs an automatic bending method, where the bending component serves as a bending die. The strip stator core is placed and positioned within the bending component, and the bending drive mechanism drives the bending component to bend and deform, thus bending the strip stator core into an annular stator core with the winding portion facing outwards. Alternatively, it can be operated manually. For example, the strip stator core is placed in the bending die, and the bending die is manually bent to form an annular stator core with the winding portion facing outwards.

[0074] When winding the outward-facing annular stator, a single-head winding machine 20 can be used to wind the stator on a single sub-stator core. By rotating the annular stator core, the annular stator core can be wound across slots, and the winding can be performed on each sub-stator core to complete the stator winding work.

[0075] The straightening machine 30 may include a straightening device 31 for unfolding and straightening the annular stator to form a strip stator. The straightening device 31 may include a first straightening component 311 and a second straightening component. When unfolding and straightening the annular stator with the winding portion facing outward, the movable and unfoldable first straightening component 311 can be inserted into the space enclosed by the annular stator. By operating the first straightening component 311 to expand and move, the annular stator is unfolded. The second straightening component may include two opposing clamping plates. The unfolded strip stator is clamped and pressed by the two opposing clamping plates to straighten the strip stator, so that the motor stator completes the winding operation. Alternatively, it can be performed manually, for example, by manually placing the annular stator into a stretching die. By stretching the die from a curved state to a straight state, the annular stator located in the die can be stretched and unfolded.

[0076] The stator winding production line 100 may also include a control device as the main execution body. The control device may be a host computer, which can be used to control the operation of the entire stator winding production line 100, that is, to control the coordinated operation of the bending machine 1010, the winding machine 20, the straightening machine 30 and the transfer device 40.

[0077] Understandably, in practical applications, the motor stator is wound in a ring shape. Adjacent stator core segments are connected on the side furthest from the rotor to form a connecting section, while the side closer to the rotor remains unconnected, forming an open winding section. Since the spacing between adjacent stator core segments gradually decreases from the outside in, the spacing near the center of the stator core is extremely small, meaning the opening in the winding section is very small. Therefore, winding the finished stator core in a ring shape is quite difficult, whether winding from the outer connecting section or the inner winding section. Currently, the finished stator core is unwound to form a straight stator core, increasing the spacing of the winding section openings. Winding at this point reduces the difficulty. However, at the same time, when winding a straight stator core, the winding machine 20 needs to be arranged along the length of the straight stator core, which takes up a lot of space, resulting in a large footprint for the straight stator winding equipment. Furthermore, after the winding is completed, the stator needs to be bent and shaped into a circle. Due to tension and deformation, the distance between the coil and the iron core, as well as the wire diameter, change after the coil and cross wire are bent into a circle, resulting in some defective products.

[0078] Therefore, the present invention uses a bending machine 10 to bend the strip stator core into a circular annular stator core, so that the connecting part of the adjacent sub-stator core segments is located on the inner side of the annular stator core, and the winding part of the adjacent sub-stator core segments is located on the outer side. Since the spacing between the adjacent sub-stator core segments in the annular stator core increases from the inside to the outside, the spacing of the opening of the winding part can be increased when the stator core is bent in the opposite direction. When winding on the outer side of the annular stator core, the annular stator core can rotate accordingly. The winding device 22 only needs to be arranged in a position opposite to a single sub-stator core, and there is no need to arrange the winding machine 20 along the length direction of the straight stator, which can greatly reduce the space occupied by the winding machine 20, thereby reducing the floor space of the stator winding equipment.

[0079] Furthermore, when the stator core is wound in the reverse circular state, the winding between adjacent segments of the sub-stator core can fit more closely to the winding slots of the sub-stator core by rotating the stator core in coordination with cross-slot winding.

[0080] Furthermore, due to the larger distance between the outer sides of the stator core of adjacent segments, winding is easier, resulting in a tighter winding coil, a more orderly wire arrangement, and a coil shape that is closer to an ideal trapezoid. The stress on the enameled wire is reduced, allowing for more accurate control of the distance between the coil and the core, and also improving the slot fill factor.

[0081] At the same time, improving the neatness of the enameled wire arrangement can increase product yield, reduce scrap caused by damage and defects due to winding, thereby reducing the amount of winding per stator, lowering production costs, and achieving a higher degree of lean manufacturing.

[0082] The technical solution of this invention controls the bending machine 10 to bend the strip stator core in the opposite direction to form an annular stator core with the winding section facing outward. This results in a larger distance between the unconnected parts on the outer side of adjacent stator core segments. When the winding machine 20 winds the wire from the winding section on the outer side of the annular stator core, the distance between the coil and the core can be accurately controlled, making the wire arrangement more neat and the coil shape closer to the ideal trapezoid. This can improve the slot fill factor and reduce the stress on the enameled wire. Furthermore, when winding the annular stator core from the winding section to form an annular stator, a single-head winding machine 20 can be used in conjunction with the rotation of the annular stator core, which can reduce the space occupied by the winding machine 20 and thus reduce the floor space of the stator winding equipment. Then, by controlling the straightening machine 30 to unfold and straighten the annular stator to form a strip stator, the winding difficulty of the motor stator can be effectively reduced, the winding quality can be improved, and the floor space of the stator winding equipment can be reduced.

[0083] Optionally, the bending machine 10 includes a bending device 11, which includes a bending component and a bending drive mechanism. The bending component has a strip-shaped state and an annular state. The bending drive mechanism is used to drive the bending component to switch between the strip-shaped state and the annular state. The steps of feeding the strip stator core to the bending machine 10 and controlling the bending machine 10 to bend the strip stator core into an annular stator core with the winding portion facing outward include:

[0084] The bending drive mechanism is controlled to drive the bending component to a strip state, and the strip stator core is positioned on the bending component in the strip state. The bending drive mechanism is controlled to drive the bending component to bend and deform, so as to switch the bending component from the strip state to the ring state, and bend the strip stator core to form a ring stator core with the winding part facing outward.

[0085] The bending component 112 can be configured as a flexible component. A bending drive mechanism can be controlled by a control device to straighten both ends of the bending component 112, placing it in a strip-shaped state. Alternatively, the bending drive mechanism can be controlled by the control device to wrap the bending component 112 around a cylindrical positioning structure, placing it in a ring-shaped state. A limiting groove extending along the length of the bending component 112 can be provided. When the bending component 112 is in a strip-shaped state, the strip stator core is inserted into the limiting groove for positioning. When the bending component 112 is switched from a strip-shaped state to a ring-shaped state, the deformation of the bending component 112 causes the strip stator core to deform synchronously, thereby achieving a reverse bending operation of the strip stator core.

[0086] With this configuration, the bending member 112 can be used as a bending operation mold, allowing the stator core to be precisely deformed according to the deformation of the bending member 112. This is beneficial for accurately bending the strip stator core into a ring shape and preventing the stator core from being poorly bent.

[0087] Understandably, when bending the straight stator core of a motor in the reverse direction to form an annular stator core with the winding portion facing outward, the two ends of the bent annular stator core are generally not welded and fixed because the wound annular stator core needs to be unfolded and straightened later. To prevent the bent annular stator core from springing back and deforming due to residual stress, the annular stator core needs to be shaped. Optionally, the bending machine 10 also includes a mold-feeding device 12. Before the step of controlling the winding machine 20 to wind the winding portion on the outer periphery of the annular stator core to form the annular stator, the device 12 is further used to install a mold onto the annular stator core to shape the annular stator core and maintain it in the bent annular state.

[0088] The mold may have an insertion portion inserted into the area enclosed by the annular stator core, and a limiting portion surrounding the outside of the mold. The limiting portion cooperates with the insertion portion to clamp the annular stator core between the insertion portion and the limiting portion, thereby shaping the annular stator core. The mold-feeding device 12 may include a first clamping member 122, a second clamping member 123, and a transfer platform 124. The first clamping member 122 is used to clamp the mold 50 and move the mold 50 to the transfer platform 124. The second clamping member 123 is used to clamp the annular stator core 1 and install the annular stator core 1 into the mold 50 to shape the annular stator core 1. With this configuration, the mold can be installed onto the annular stator core by controlling the mold feeding device 12, so that the annular stator core in the intermediate state can be effectively shaped, keeping the annular stator core in the bent annular state, avoiding the annular stator core from springing back and deforming due to residual stress, and also preventing the annular stator core from deforming due to the winding tension of the winding machine 20 during the winding process.

[0089] In addition, when the annular stator core is shaped using a mold, to avoid the mold's influence on the unfolding of the annular stator into a strip stator, the annular stator can be separated from the mold before unfolding and straightening. Optionally, the straightening machine 30 further includes a demolding device 32, which further includes controlling the demolding device 32 to separate the annular stator from the mold before the step of controlling the straightening machine 30 to unfold and straighten the annular stator into a strip stator.

[0090] The demolding device 32 can adopt the same structure as the mold-feeding device 12. The separation of the annular stator from the mold can be carried out in the opposite direction of the installation of the annular stator and the mold. For example, the mold 50 and the annular stator are clamped separately, so that the annular stator and the mold are far apart. This arrangement can avoid the mold from affecting the unfolding operation of the annular stator. For example, the presence of the mold makes it inconvenient to clamp and position the annular stator core, thus making it inconvenient to stretch and unfold the annular stator core, or the presence of the mold makes it inconvenient to put the annular stator core into the stretching mold and unfold the annular stator into a strip stator by deforming the stretching mold.

[0091] The following describes in further detail the steps of unfolding and straightening the annular stator to form a strip stator annular shape. Optionally, the straightening machine 30 includes a straightening device 31, which includes a first straightening component 311 and a second straightening component 312. The step of controlling the straightening machine 30 to unfold and straighten the annular stator to form a strip stator includes:

[0092] The step of unfolding and straightening the annular stator to form a strip stator includes:

[0093] S301: Control the first straightening component 311 to unfold the annular stator to form a strip stator;

[0094] S302: Control the second straightening component 312 to perform pressure-holding straightening on the unfolded strip stator.

[0095] In this way, the unfolding and straightening of the annular stator can be carried out in two steps. The stator straightening effect can be increased by holding the pressure twice, and the stator can be prevented from springing back and deforming due to residual stress.

[0096] The first straightening assembly 311 may include two movable operating members. When unfolding the annular stator into a strip stator, the annular stator can be positioned on a positioning plate, and the two movable operating members can be inserted into the area enclosed by the annular stator. The annular stator is then clamped between the positioning plate and the operating members, and the two operating members move away from each other, causing the annular stator to unfold into a strip stator while adhering to the positioning plate. The second straightening assembly 312 may include a pressure plate disposed opposite to the positioning plate. When straightening the unfolded strip stator under pressure, the pressure plate can move towards the strip stator adhering to the positioning plate, clamping the strip stator between the pressure plate and the positioning plate. This pressure-holding method prevents poor straightening due to residual stress rebound.

[0097] The following describes in more detail the steps of winding a toroidal stator core to form a toroidal stator. Optionally, the winding machine 20 includes a winding limiting device 21 and a winding device 22. The step of controlling the winding machine 20 to wind the winding portion on the outer periphery of the toroidal stator core to form a toroidal stator includes:

[0098] S201: The annular stator core is placed in the winding limiting device 21;

[0099] S202: Control the winding device 22 to wind from the winding section on the outer periphery of the annular stator core, and control the winding limiting device 21 to drive the annular stator core to rotate axially, so that multiple winding sections on the outer periphery of the annular stator core sequentially face the winding device 22 to complete the winding, thereby obtaining an annular stator.

[0100] Understandably, during the winding process of the stator core in the slots, the wire will wrap around the slots during its reciprocating motion. This reciprocating motion of the wire will cause the annular stator core to move up and down. Therefore, the annular stator core is first positioned in the winding limiting device 21 to limit its movement and prevent it from detaching from its original winding position. Simultaneously, when the winding limiting device 21 limits the annular stator core, it can also drive the annular stator core to rotate synchronously along the axial direction. When the winding device 22 winds the annular stator core, a single-head winding device 22 can be used to wind across the slots on the annular stator core facing the winding device 22, eliminating the need to move the winding device 22. This saves space in the stator winding equipment.

[0101] like Figures 2 to 17 As shown, the present invention also proposes a stator winding production line 100, which uses the stator winding method described above for winding. The stator winding production line 100 includes a bending machine 10, a winding machine 20, and a straightening machine 30. Since this stator winding production line 100 adopts all the technical solutions of all embodiments of the above-described stator winding method, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated further here. Specifically, the bending machine 10 is used to bend the strip stator core in the reverse direction to form an annular stator core 1 with the winding portion facing outward; the winding machine 20 is used to receive the annular stator core 1 and to wind it to form an annular stator; and the straightening machine 30 is used to unfold and straighten the annular stator to form a strip stator.

[0102] The stator winding production line 100 of the present invention may further include a transfer device 40, which is connected in sequence to the bending machine 10, the winding machine 20 and the straightening machine 30. The transfer device 40 is used to transport the bent annular stator core 1 to the winding machine 20 and to transport the wound annular stator to the straightening machine 30.

[0103] The transfer device 40 has an input end near the bending machine 10 and an output end near the straightening machine 30. The transfer device 40 feeds a mold 50, which carries the annular stator core 1, from its input end. The operator feeds the strip stator core to the bending machine 10, which bends the strip stator core in the opposite direction into an annular shape, forming the annular stator core 1. The winding portion of the annular stator core 1 is located on the outside of the annular stator core 1. After assembling the mold 50 on the transfer device 40 with the annular stator core 1, the transfer device... The device 40 is moved to the winding machine 20, which takes the material from the transfer device 40 and winds it to form a reverse-curved annular stator. The winding machine 20 then places the material on the transfer device 40 and transfers it to the straightening machine 30. The straightening machine 30 takes the annular stator with the mold 50, demolds the mold 50, straightens and unfolds the annular stator to form a strip stator. At the same time, the demolded mold 50 is moved to the transfer device 40 and unloaded through the output end of the transfer device 40, completing the winding of the stator.

[0104] The stator winding production line 100 of the present invention may further include a control device as the execution subject. The control device can be used to control the operation of at least one of the bending machine, the winding machine, and the straightening machine. The control device may be a host computer, which is used to control the operation of the entire stator winding production line 100, that is, to control the bending machine 10, the winding machine 20, the straightening machine 30 and the transfer device 40 to operate in a coordinated manner.

[0105] With this configuration, the bending machine 10 can be controlled by the control device to bend the straight stator core in the opposite direction to form an annular stator core 1 with the winding portion facing outward. The winding machine 20 can also be controlled by the control device to receive the annular stator core 1. During the winding of the annular stator core 1, the winding can be performed through the outer winding portion of the annular stator core 1 within the winding slot of the annular stator core 1. This increases the winding space of the winding and improves the winding quality. Furthermore, the position of the winding portion of each sub-stator core 1a can be changed by rotating the annular stator core. Each stator core 1a can be sequentially positioned opposite the winding machine 20, allowing the winding machine 20 to perform the motor stator winding operation using a single-head winding method. This reduces the space occupied by the winding machine 20, thereby reducing the floor space of the stator winding production line 100. Subsequently, the straightening machine 30 can be controlled by the control device to straighten the reverse-bent motor stator, thus completing the winding on the motor stator core. Compared with existing technologies, this method can effectively reduce the floor space of the stator winding production line 100 while improving the stator winding quality.

[0106] The bending machine 10, winding machine 20, and straightening machine 30 will be introduced step by step below.

[0107] like Figure 3 , Figure 4 , Figure 5As shown, in one embodiment, the bending machine 10 includes a bending device 11, which includes a bending component 112 and a bending drive mechanism 115. The bending component 112 has a strip-shaped state and an annular state. The bending drive mechanism 115 is used to drive the bending component 112 to switch between the strip-shaped state and the annular state. The bending component 112 is used to position the strip stator core in the strip-shaped state and to bend the strip stator core in the reverse direction to form an annular stator core 1 with the winding portion facing outward during the process of switching from the strip-shaped state to the annular state.

[0108] The bending member 112 can be configured as a flexible component. It can be straightened at both ends to achieve a strip shape, or wrapped around a cylindrical positioning structure to achieve an annular shape. A limiting groove extending along the length of the bending member 112 can be provided. When the bending member 112 is in its strip shape, the strip stator core is inserted into the limiting groove for positioning. When the bending member 112 is switched from its strip shape to its annular shape, the deformation of the bending member 112 causes the strip stator core to deform synchronously, thus achieving a reverse bending operation of the strip stator core. The bending drive mechanism 115 can drive the two ends of the bending component 112 respectively. By operating the two ends of the bending component 112 to move closer or farther apart, and with the bending component 112 positioned by the cylindrical positioning structure, the bending component 112 can be switched between a strip state and a ring state.

[0109] See Figure 4 , Figure 5 As shown, in one embodiment, the bending drive mechanism 115 includes a bending drive member 1151 and two swing arms 1152. The two swing arms 1152 are movably connected to both ends of the bending member 112, and the ends of the two swing arms 1152 away from the bending member 112 are respectively connected to the bending drive member 1151. The bending drive member 1151 is used to drive the two swing arms 1152 to expand or close relative to each other, so as to drive the bending member 112 to switch between a strip state and a ring state.

[0110] The other end of the swing arm 1152 can be rotated around the rotating part 1152a. When both swing arms 1152 are rotated around the corresponding rotating part 1152a, the two swing arms 1152 can be rotated around the rotating part 1152a to make the two swing arms 1152 relatively open or relatively close, so that the ends of the two swing arms 1152 connected to the bending member 112 are relatively far apart or relatively close. The bending drive member 1151 can drive the two swing arms 1152 to rotate around the rotating part 1152a respectively, bending the straight stator core positioned in the bending member 112 to form an annular stator core with the ends connected.

[0111] When the swing arm 1152 moves to switch the curved component 112 between a strip shape and a ring shape, in order to ensure that the curved component 112 can be accurately bent into a ring shape and to ensure that the curved component 112 can be accurately unfolded into a strip shape, please refer to [further details]. Figure 4 , Figure 5 In one embodiment, the bending device 11 further includes a first positioning member 113 and a second positioning member 114 disposed opposite to each other along a first direction. The bending member 112 is used to fit against the side of the first positioning member 113 facing the second positioning member 114 when it is in a strip state, and to fit against the outer surface of the second positioning member 114 when it is in a ring state.

[0112] The bending member 112 can be disposed between the first positioning member 113 and the second positioning member 114. The side of the first positioning member 113 facing the second positioning member 114 can be set in a planar shape, and the outer surface of the second positioning member 114 can be set in a circular shape. Thus, when the two ends of the bending member 112 are brought together by the two swing arms 1152, the bending member 112 can fit against the outer surface of the second positioning member 114, thereby limiting the bending member 112 into a circle, and thus bending the stator core positioned in the bending member 112 into a circle. When the two ends of the bending member 112 are moved away from each other and change into a strip shape by the two swing arms 1152, the bending member 112 can be positioned on the plane of the first positioning member 113 facing the second positioning member 114, so that the bending member 112 can be reset into a strip shape, thereby facilitating the subsequent positioning of the next straight stator core on the bending member 112.

[0113] With the first positioning member 113 and the second positioning member 114 provided, in order to simplify the process of the bending drive member 1151 driving the two swing arms 1152 to move, and thus make it easier for the bending drive mechanism 115 to drive the bending member 112 to switch between the strip state and the ring state, the bending drive mechanism 115 may optionally include a transmission plate 1153 movably arranged along the first direction. The ends of the two swing arms 1152 away from the bending member 112 are respectively hinged to the transmission plate 1153. The bending drive member 1151 is used to drive the transmission plate 1153 to move along the first direction, so as to drive the two swing arms 1152 to spread out or move closer to each other.

[0114] The two swing arms 1152 are symmetrically connected to both sides of the transmission plate 1153. A first base 111 can be provided, and the transmission plate 1153 can be slidably mounted on the first base 111 along a first direction. The first positioning member 113 and the second positioning member 114 can also be provided on the first base 111. When the bending drive member 1151 drives the transmission plate 1153 to move toward the first positioning member 113 along the first direction, when the bending member 112 abuts against the first positioning member 113, the bending member 112 is straightened, thereby driving the bending member 112 to move toward the first positioning member 113. The two swing arms 1152 are connected and swing to extend. When the curved part 112 moves from the first positioning part 113 to the second positioning part 114, the transmission plate 1153 pushes the curved part 112 toward the second positioning part 114 through the two swing arms 1152 and attaches it to the outer surface of the second positioning part 114. During the process of the curved part 112 attaching to the outer surface of the second positioning part 114, the curved part 112 drives the two swing arms 1152 and the end connected to the curved part 112 to move closer to each other, so that the two swing arms 1152 are relatively close.

[0115] This configuration allows the bending member 112 to switch between a strip-shaped state and a ring-shaped state simply by driving the transmission plate 1153 linearly through the bending drive member 1151. It eliminates the need to drive the two swing arms 1152 to rotate around the rotating part 1152a separately, making it simpler for the bending drive mechanism 115 to drive the bending member 112 to switch between a strip-shaped state and a ring-shaped state.

[0116] To ensure that the curved part 112 can completely fit the outer surface of the second positioning part 114 when it is in an annular state, such as Figure 6 , Figure 7 As shown, optionally, the bending device 11 further includes a positioning component 116, which includes a first gripper 1161. The first gripper 1161 is used to clamp the two ends of the bending component 112 when the bending component 112 is in an annular state, and to bring the two ends of the bending component 112 closer to each other so that the bending component 112 fits against the peripheral side of the second positioning component 114.

[0117] The positioning component 116 may be located on the side of the second positioning member 114 away from the first positioning member 113. The positioning component 116 may also include a first positioning drive member 1164, which can drive the first gripper 1161 to move toward the second positioning member 114 in a first direction. The first gripper 1161 may include two first gripper portions, which are set at an angle to each other. The distance between the two first gripper portions decreases from one end closer to the second positioning member 114 to the other end. When the bending drive mechanism 115 drives the bending member 112 to switch to the annular state, the first positioning drive member 1164 can drive the first gripper 1161 to move toward the second positioning member 114, so that the two ends of the bending member 112 are inserted into the positioning groove 1161a between the two first gripper portions, and move closer to each other as the first gripper 1161 moves toward the second positioning member 114, so that the two ends of the bending member 112 can be as close as possible, ensuring the bending effect of the bending member 112 in the annular state.

[0118] In order to enable the end of the bent circular part 112 to be effectively inserted into the positioning groove 1161a between the two second gripper portions, optionally, the end of the bent circular part 112 is provided with a positioning rod 1122, which is inserted into the positioning groove 1161a, so as to facilitate the positioning of the end of the bent circular part 112 in the positioning groove 1161a.

[0119] In addition, when the bent component 112 is in an annular state, in order to further approximate the shape of the annular stator core 1 after bending to facilitate accurate positioning during subsequent winding, such as... Figure 5 , Figure 6 As shown, optionally, the positioning component 116 further includes a second gripper 1162, which is used to grip the beginning and end ends of the annular stator core 1 when the bent circular piece 112 is in an annular state, and to bring the beginning and end ends of the annular stator core 1 closer to each other.

[0120] The second gripper 1162 can be driven by the first positioning drive 1164 to move closer to or further away from the second positioning member 114 in the first direction. The second gripper 1162 may include two second gripper portions. The positioning assembly 116 may also include a second positioning drive 1163 for driving the two second gripper portions to move closer to or further away from each other. When the bending drive mechanism 115 drives the bending member 112 to switch to the annular state, the first positioning drive 1164 can drive the second gripper portions to move toward the second positioning member 114, placing the two ends of the annular stator core 1 between the two second gripper portions. The second positioning drive 1163 drives the two second gripper portions to move closer to each other, so that the two ends of the annular positioning core are further close, thereby enabling the annular stator core 1 to fit tightly against the bending member in the annular state, so as to perform preliminary shaping of the annular stator core 1 after bending, and avoid the annular stator core 1 from deforming due to stress rebound.

[0121] like Figure 5 As shown, in one embodiment, the bent circular component 112 includes a plurality of chain links 1121 connected in sequence. Each chain link 1121 has a receiving groove. The plurality of receiving grooves are connected in sequence to form a limiting groove 112a. The limiting groove 112a is used to limit the placement of the annular stator core 1.

[0122] It is understandable that when the bending component 112 is configured as multiple sequentially movable links 1121, since each link 1121 has a certain rigidity, the multiple links 1121 can be configured one-to-one with the multiple sub-stator cores 1a of the stator core. Each sub-stator core 1a can be placed in the receiving groove of each link 1121. In this way, when the bar stator core is bent in the reverse direction, the rigid link 1121 can form protection for a single sub-stator core 1a. When two adjacent links 1121 are bent, the connection between the two adjacent sub-stator cores 1a can be bent, without causing the sub-stator core 1a to bend itself. This can prevent the sub-stator core 1a from being deformed by bending stress.

[0123] Furthermore, after the stator core is bent in the reverse direction, since its two ends are not welded and fixed, it is very easy to deform when it is removed from the bending part 112. To prevent the annular stator bent in the reverse direction from deforming during subsequent winding operations, thus affecting the winding, such as... Figure 3 , Figure 8 , Figure 9 As shown, the bending machine 10 also includes a mold-feeding device 12, which includes a first clamping member 122, a second clamping member 123, and a transfer platform 124. The first clamping member 122 is used to clamp the mold 50 and move the mold 50 to the transfer platform 124. The second clamping member 123 is used to clamp the annular stator core 1 and install the annular stator core 1 onto the mold 50 to shape the annular stator core 1.

[0124] The mold-feeding device 12 may further include a mold-feeding track 121, with a first clamping member 122 and a second clamping member 123 movably mounted on the mold-feeding track 121 along a first direction. A first mold-feeding drive member may also be provided to drive the first clamping member 122 to move along the first direction, so that the first clamping member 122 can move to directly above the mold 50 and directly above the transfer platform 124, thereby allowing the first clamping member 122 to move the clamped mold 50 onto the transfer platform 124. A second mold-feeding drive member may also be provided to drive the second clamping member 123 to move along the first direction, so that the second clamping member 123 can move to directly above the bent annular stator core 1 and directly above the transfer platform 124, thereby allowing the annular stator core 1 to be clamped and obtained by the second clamping member 123, and then the annular stator core 1 to be installed onto the mold 50 on the transfer platform 124, thus achieving the shaping of the annular stator core 1.

[0125] In addition, the first mold entry drive can also drive the first clamping member 122 to move along the first direction. After the annular stator core 1 is installed on the mold 50, the annular stator core 1 can be clamped by clamping the mold 50, and the annular stator core 1 after entering the mold can be moved along the first direction to the transfer device 40, realizing the unloading operation of the annular stator core 1 on the bending machine 10. Therefore, there is no need to set up an additional unloading device, which can save costs, reduce the overall size of the bending machine 10, and further reduce the overall footprint of the stator winding production line 100.

[0126] The structure of the second clamping member 123 will be further described below, such as... Figure 9 As shown, in one embodiment, the second clamping member 123 includes a rounding drive member 1231, a second base 1232, and a plurality of third jaws 1233. The plurality of third jaws 1233 are movably disposed on the second base 1232. The plurality of third jaws 1233 are used to clamp the outer periphery of the annular stator core 1. The rounding drive member 1231 is used to drive the plurality of third jaws 1233 to move synchronously along the second base 1232 to round the annular stator core 1.

[0127] The third gripper 1233 can be disposed around the second base 1232. The third gripper 1233 moves along the second base 1232 and can swing around the second base 1232. For example, the third gripper 1233 can swing inward toward the second base 1232 to clamp the annular stator core 1. Alternatively, the third gripper 1233 can swing outward toward the second base 1232 to release the annular stator core 1.

[0128] Since the rounding drive 1231 can drive multiple third grippers 1233 to move synchronously along the second base 1232, the multiple third grippers 1233 can apply pressure to each part of the annular stator core 1 along the same movement path. When each segment of the annular stator core 1 is respectively attached to the multiple third grippers 1233, the annular stator core 1 can be adjusted by the multiple third grippers 1233 to become as round as possible, thereby achieving the roundness of the annular stator core 1 and ensuring the roundness of the annular stator core 1.

[0129] The following section provides further details on how to drive the synchronized movement of multiple third grippers 1233. Please refer to the following for further information. Figure 9 In one embodiment, the second clamping member 123 further includes a movable plate 1234, which is rotatably mounted on the second base 1232 along the axial direction of the second base 1232. The movable plate 1234 has a plurality of adjustment grooves 1234a spaced apart along the circumference of the second base 1232. Each adjustment groove 1234a has a first end near the axis of the second base 1232 and a second end away from the axis of the second base 1232. The plurality of adjustment grooves 1234a are paired with a plurality of third grippers 1233. Each third gripper 1233 has a linkage part 1233a movably disposed in the corresponding adjustment groove 1234a. The full-circle driving member 1231 is used to drive the movable plate 1234 to rotate axially, so as to drive the linkage part 1233a of each third gripper 1233 to reciprocate between the first end and the second end, thereby driving each third gripper 1233 to swing along the second base 1232.

[0130] The end of the circular drive component 1231 connected to the movable plate 1234 can be hinged to the movable plate 1234, and the third gripper 1233 can be hinged to the periphery of the second base 1232. When the adjusting grooves 1234a are distributed circumferentially around the second base 1232, and the first end of the adjusting grooves 1234a is close to the axis of the second base 1232, and the second end of the adjusting grooves 1234a is close to the axis of the second base 1232, the extending direction of the adjusting grooves 1234a is inclined relative to the tangential direction of the second base 1232.

[0131] When the circular drive 1231 drives the movable plate 1234 to rotate, the position of the adjusting groove 1234a relative to the second base 1232 changes. The third gripper 1233 is hinged to the second base 1232. When the position of the adjusting groove 1234a changes, causing the linkage part 1233a of the third gripper 1233 to move between the first and second ends, it can cause the third gripper 1233 to swing relative to the second base 1232. Since each third gripper 1233 corresponds to an adjusting groove 1234a, the movement of multiple adjusting grooves 1234a can drive multiple third grippers 1233 to operate simultaneously, thereby achieving the clamping and release of the annular stator core 1. When clamping the annular stator core 1, the circular drive 1231 drives the movable plate 1234 to rotate, adjusting the amplitude of the simultaneous swing of multiple third grippers 1233, thus achieving the circularization of the annular stator core 1.

[0132] The following section provides further details about the straightening machine 30; please refer to [link / reference]. Figure 11 As shown, the straightening machine 30 includes a demolding device 32 and a straightening device 31. The demolding device 32 is used to receive the annular stator with the mold 50 and to separate the annular stator from the mold 50. The straightening device 31 is used to unfold the demolded annular stator to form the strip stator.

[0133] Understandably, when the annular stator core 1 is shaped by the mold 50, to avoid the mold 50 affecting the unfolding of the annular stator into a strip stator when it is unfolded and straightened by the straightening machine 30, the annular stator can be separated from the mold 50 before unfolding and straightening. Therefore, the straightening machine 30 includes a demolding device 32 and a straightening device 31. The demolding device 32 separates the annular stator from the mold 50, preventing the mold 50 from affecting the unfolding operation of the annular stator. After the annular stator is demolded, the straightening device 31 straightens the annular stator core 1.

[0134] Optionally, the demolding device 32 includes a placement component 321 and a demolding component 322;

[0135] The placement assembly 321 is used to place the annular stator with the mold 50. The demolding assembly 322 includes a third clamping member and a pressing demolding head. The third clamping member is used to clamp the outer periphery of the annular stator. The pressing demolding head is used to move in a direction toward the placement assembly 321 to eject the mold 50 located in the annular stator.

[0136] The pressing demolding head can move in the up and down direction to push out the mold 50 located in the annular stator. In the above embodiment, the third clamping member can be set on the outer periphery of the placement component 321 to clamp and fix the annular stator placed in the placement component 321. The pressing demolding head can be set directly above the placement component 321 or directly below the placement component 321. The pressing demolding head can be operated automatically or manually to move along the axial direction of the annular stator toward the mold 50, pushing the mold 50 out from top to bottom or from bottom to top, so that the annular stator completes the demolding operation.

[0137] When unfolding and straightening the annular stator core 1, in order to ensure the unfolding and straightening effect of the annular stator core 1, unfolding and straightening can be carried out separately. Optionally, the straightening device 31 includes a first straightening component 311 and a second straightening component 312. The first straightening component 311 is used to unfold the annular stator to form a strip stator, and the second straightening component 312 is used to hold pressure on the strip stator to straighten the strip stator.

[0138] In the process of unfolding and straightening the annular stator, the first straightening component 311 unfolds the annular stator into a strip stator, and the second straightening component 312 performs secondary pressure holding on the unfolded strip stator, which can increase the stator straightening effect and prevent the stator from springback deformation due to residual stress.

[0139] Please see Figure 14 , Figure 15 , Figure 16 The straightening machine 30 also includes a worktable 33 and a positioning plate 34. The worktable 33 is used to place the annular stator, and the positioning plate 34 is disposed on the worktable 33. The first straightening component 311 is disposed opposite to the positioning plate 34. The first straightening component 311 may include two rollers 3111. The two rollers 3111 are used to be inserted into the area enclosed by the annular stator and to abut the annular stator against the positioning plate 34. The two rollers 3111 are used to reciprocate along the extension direction of the positioning plate 34, moving closer or further away from each other, so as to unfold the annular stator into a strip stator.

[0140] During operation, with the two rollers 3111 inserted into the inner cavity of the annular stator, the two rollers 3111 press the annular stator against the positioning plate 12, clamping the annular stator between the rollers 3111 and the positioning plate 34. Then, the two rollers 3111 reciprocate along the extension direction of the positioning plate 34, moving closer or further away from each other. When the rollers 3111 are in contact with the inner surface of the annular stator, each part of the annular stator can be pressed against the positioning plate 34 by the rollers 3111, causing the annular stator to break at the end-to-end joint and unfold along the positioning plate 34 to form a strip stator.

[0141] When the roller 3111 is in contact with the surface of the annular stator and moves back and forth along the extension direction of the positioning plate 34, the contact friction between the roller 3111 and the surface of the annular stator can be reduced, thereby reducing damage to the surface of the annular stator and avoiding damage to the core and windings of the annular stator.

[0142] like Figure 15 , Figure 16 As shown, optionally, the first straightening assembly 311 further includes a first straightening drive 3112, which drives the two rollers 3111 to move closer or further apart relative to each other along the direction of extension of the positioning plate 34. The first straightening drive 3112 may be configured as two cylinders, each of which can drive the two rollers 3111 respectively.

[0143] Alternatively, the first straightening drive 3112 can be used to drive the roller 3111 to move closer to or away from the positioning plate 34 in a direction opposite to the positioning plate 34. In this case, two first straightening drive 3112s can be provided, each of which is used to drive the two rollers 3111 to move closer to or away from the positioning plate 34 in a direction opposite to the positioning plate 34. When the two rollers 3111 are driven to move closer to the positioning plate 34, the rollers 3111 can push the annular stator, causing the annular stator to be clamped between the rollers 3111 and the positioning plate 34.

[0144] Alternatively, the first straightening drive unit 3112 can simultaneously achieve the above-mentioned driving methods, without specific limitations here.

[0145] like Figure 15 , Figure 16 As shown, in one embodiment, the first straightening assembly 311 further includes a straightening mounting member 3113, which elastically connects the roller 3111 to the first straightening drive member 3112, so that the roller 3111 elastically floats relative to the positioning plate 34.

[0146] The straightening mounting component 3113 can be configured as a mounting frame for mounting the roller 3111. The mounting frame can be connected to the output end of the first straightening drive component 3112. The mounting frame can include a first section that is drivenly connected to the first straightening drive component 3112 and a second section for mounting the roller 3111. The first section and the second section can be linearly and movably connected, and the first section and the second section can be elastically connected by an elastic member.

[0147] In this way, when the roller 3111 moves toward the positioning plate 34 in the direction opposite to the positioning plate 34 and comes into contact with the annular stator, it can avoid the roller 3111 from having a rigid collision with the annular stator, which would cause damage to the annular stator. When the annular stator is configured as an annular stator, the stator core and stator winding can be further prevented from being damaged by elastic buffer.

[0148] Furthermore, when the first straightening drive 3112 drives the roller 3111 to roll on the stator surface, it can not only reduce the friction between the roller 3111 and the stator surface, but also allow the roller 3111 to have a certain slight floating relative to the stator surface through the straightening mounting 3113. This reduces the rigid impact of the roller 3111 on the stator during the rolling process, especially the rigid impact on the weak part of the connection between two adjacent sub-stator cores 1a, thereby avoiding the occurrence of micro-cracks or local fractures on the stator surface due to rolling.

[0149] like Figure 15 , Figure 16 As shown, optionally, the second straightening assembly 312 includes a pressure plate 3121 disposed opposite to the positioning plate 34. The pressure plate 3121 is used to move toward the positioning plate 34 so that the strip stator is clamped by the pressure plate 3121 and the positioning plate 34.

[0150] With this configuration, after the first straightening component 311 unfolds the annular stator into a strip stator, the pressure plate 3121 moves toward the strip stator that is abutting against the positioning plate 34, pressing against the strip stator. This clamps the strip stator between the pressure plate 3121 and the positioning plate 34, maintaining pressure on the strip stator and straightening it. This prevents the strip stator from springing back and shrinking, which would result in poor straightening.

[0151] In addition, to further improve the straightening effect on the strip stator, such as Figure 15 , Figure 16 As shown, in one embodiment, the second straightening assembly 312 further includes a plurality of pressure columns 3122, which are spaced apart along the length of the pressure plate 3121. Each pressure column 3122 is movably disposed on the pressure plate 3121 in a direction opposite to the positioning plate 34. When the strip stator is clamped by the pressure plate 3121 and the positioning plate 34, each pressure column 3122 is used to abut against the strip stator.

[0152] In the above embodiment, the pressure column 3122 can be movably disposed on the pressure plate 3121 in a direction opposite to the positioning plate 34 by means of a threaded connection with the pressure plate 3121, which is not limited here. When the pressure plate 3121 and the positioning plate 34 cooperate to clamp the strip stator, each pressure column 3122 can move independently in a direction opposite to the positioning plate 34 and abut against the strip stator, which can further maintain pressure on each section of the sub-stator core 1a of the strip stator, thereby increasing the pressure holding effect.

[0153] The structure of the winding machine 20 will be further described below. (See attached document.) Figure 10 , Figure 11As shown, in one embodiment, the winding machine 20 includes a winding limiting device 21 and a winding device 22. The winding limiting device 21 is used to limit the placement of the annular stator core 1 and to drive the annular stator core 1 to rotate axially. The winding device 22 is used to wind wire on the winding portion outside the annular stator core 1 to form an annular stator.

[0154] like Figure 11 As shown, the winding limiting device 21 may include a placement component 211 and a limiting engagement component 212. The placement component 211 has a winding position for winding the annular stator core 1. The placement component 211 includes a winding platform 2111 and a first rotation drive component 2112. The winding platform 2111 is used to limit the placement of the annular stator core 1 to be wound. The first rotation drive component 2112 is used to drive the winding platform 2111 to rotate about the axial direction. The limiting engagement component 212 includes a third base 2121 and a limiting platform 2122 rotatably mounted on the third base 2121. When the placement component 211 is in the winding position, the limiting platform 2122 and the winding platform 2111 are arranged opposite to each other along the axial direction of the annular stator core 1. The limiting platform 2122 is used to limit the contact with the annular stator core 1 and can rotate synchronously with the winding platform 2111 when it contacts the annular stator core 1.

[0155] The winding table 2111 can be axially oriented vertically. The winding table 2111 can be equipped with a clamping structure to clamp and limit the non-winding portion of the annular stator core 1, thus limiting the annular stator core 1 to its position on the winding table 2111. Alternatively, the winding table 2111 can be equipped with an insertion limiting structure to cooperate with the mold 50 on which the annular stator core 1 is installed, thus limiting the annular stator core 1 to its position on the winding table 2111. Or, the winding table 2111 can simultaneously limit the annular stator core 1 using both of the above methods. It is understood that, similar to the winding table 2111, the limiting table 2122 can also adopt the aforementioned limiting structure.

[0156] Furthermore, during the winding process on the winding section, the annular stator core 1 is driven by the winding and subjected to the axial force. When the limiting fitting assembly 212 moves axially, the limiting platform 2122 and the annular stator core 1 are limited and abutted. This prevents the annular stator core 1 from being unable to be effectively limited on the winding platform 2111 during winding. Moreover, when the limiting platform 2122 abuts against the annular stator core 1, it can rotate with the rotation of the annular stator core 1 without affecting the limiting effect on the annular stator core 1. This avoids relative deflection between the annular stator core 1 and the limiting platform 2122, which could lead to the annular stator core 1 being not securely fixed or damaged. When the winding portion facing the winding device 22 completes the winding to form the winding 22, the first rotary drive 2112 drives the winding table 2111 to rotate axially, adjusting the winding portion of the next unwound sub-stator core 1a to face the winding device 22 for winding. When the winding table 2111 drives the annular stator core 1 to complete one revolution, the winding portion of each sub-stator core 1a of the annular stator core 1 is completed, and the annular stator core 1 is completed to form an annular stator.

[0157] like Figure 12 , Figure 13 As shown, in one embodiment, the limiting platform 2122 includes a base 21221, a first limiting part 21222, and a second limiting part 21223. The first limiting part 21222 and the second limiting part 21223 are disposed on the base 21221. The first limiting part 21222 is used to restrict the annular stator core 1 from moving axially relative to the base 21221, and the second limiting part 21223 is used to restrict the annular stator core 1 from rotating axially relative to the base 21221.

[0158] The base 21221 is used to install the first limiting part 21222 and the second limiting part 21223. The first limiting part 21222 can abut against the side of the annular stator core 1 away from the winding table 2111 along the axial direction. When the other side of the annular stator core 1 is limited, both sides of the annular stator core 1 are limited along the axial direction, thereby preventing the annular stator core 1 from deflecting up and down during winding. The second limiting part 21223 can be inserted into the annular cavity of the annular stator core 1 along the axial direction and abut against the non-annular inner wall of the annular cavity. When the annular stator core 1 rotates with the winding table 2111 to switch the winding position, the limiting table 2122 can rotate synchronously with the annular stator core 1 without affecting the position switching of the annular stator core 1.

[0159] The first limiting part 21222 and the second limiting part 21223 will be further described below. (Continue reading...) Figure 12 , Figure 13In one embodiment, the first limiting part 21222 is configured as a plurality of fourth claws arranged around the outer periphery of the base 21221, and the plurality of fourth claws are used to abut and cooperate with the side of the annular stator core 1 facing the base 21221.

[0160] The fourth gripper can be evenly spaced around the base 21221. It can be understood that when multiple fourth grippers are provided to abut against the side of the annular stator core 1 facing the base 21221, the side of the annular stator core 1 facing the base 21221 can be subjected to balanced force, which is beneficial to maintaining the force balance of the annular stator core 1.

[0161] Optionally, a clearance space is formed between adjacent fourth jaws, each clearance space being used to avoid the winding portion of the annular stator core 1.

[0162] It is understandable that the distance between two adjacent fourth jaws is not less than the maximum width of the winding 22 formed after the winding part is wound. This can prevent the fourth jaws from pressing directly down on the winding part of the annular stator core 1, causing damage to the winding part, and affecting the winding work performed on the winding part.

[0163] like Figure 13 In one embodiment, the second limiting part 21223 is configured as a first anti-deflection member. The first anti-deflection member is disposed on the side of the base 21221 near the annular stator core 1. The first anti-deflection member is used to insert and cooperate with the mold 50 for installing the annular stator core 1 to restrict the rotation of the annular stator core 1 relative to the base 21221.

[0164] The first anti-deflection component is inserted into the mold 50, allowing its sidewall to abut against the inner wall of the mold 50. When the mold 50 rotates with the annular stator core 1, the first anti-deflection component, through the engagement of its sidewall with the inner wall of the mold 50, rotates with the mold 50, thereby driving the limiting platform 2122 to rotate, thus restricting the rotation of the annular stator core 1 relative to the base 21221. The first anti-deflection component can be configured as a pin structure, and multiple first anti-deflection components can be provided, each abutting against multiple inner walls of the mold 50. This ensures the annular stator core 1 is balanced under stress while restricting its rotation relative to the base 21221.

[0165] like Figure 11 , Figure 12 As shown, in one embodiment, the limiting engagement component 212 further includes a first moving drive member 2123 that drives the third base 2121 to move closer to or away from the winding platform 2111 via the third base 2121.

[0166] The first moving drive component 2123 can be configured to drive a cylinder connected to the third base 2121. The cylinder can drive the third base 2121 to reciprocate along the axial direction of the annular stator core 1, moving closer to or away from the third base 2121. Since the limiting platform 2122 can be rotatably mounted on the third base 2121, it can drive the third base 2121 to reciprocate along the axial direction of the annular stator core 1, thereby driving the limiting platform 2122 to reciprocate along the axial direction of the annular stator core 1, moving closer to or away from the winding platform 2111. Alternatively, to facilitate the feeding of the annular stator core 1 onto the winding table 2111, the first moving drive unit 2123 can also be configured as two cylinders with their driving strokes interleaved. One set drives the third base 2121 to reciprocate along the axial direction of the winding table 2111, while the other set drives the third base 2121 to reciprocate radially along the winding table 2111. When feeding onto the winding table 2111, sufficient feeding and unloading space can be reserved for the feeding and unloading mechanisms of the winding machine 20, which facilitates the reservation of space.

[0167] like Figure 10 , Figure 11 As shown, in one embodiment, the winding limiting device 21 further includes a second moving drive 213, and the placement assembly 211 also has loading and unloading positions for loading and / or unloading. The second moving drive 213 is used to drive the winding limiting device 21 to reciprocate between the winding position and the loading and unloading position.

[0168] In this way, when the placement component 211 is loading and / or unloading, it can be driven by the second moving drive component 213 to move from the winding position to the loading / unloading position, so that the placement component 211 avoids the limiting engagement component 212 and avoids the two from being opposite each other, which would cause the limiting engagement component 212 to interfere with the loading / unloading device 23 of the winding machine 20 when the winding table 2111 is loading and / or unloading.

[0169] The loading and unloading positions can be used to place the loading annular stator core 1 of component 211, or to place the unloading annular stator of component 211, or to place both the loading annular stator core 1 and the unloading annular stator of component 211 simultaneously.

[0170] like Figure 10 As shown, in one embodiment, the winding machine 20 further includes a loading and unloading device 23, wherein, when the placement component 211 of the winding limiting device 21 is in the loading and unloading position, the loading and unloading device 23 is used to move the annular stator core 1 from the transfer device 40 to the placement component 211 of the winding limiting device 21, and to move the annular stator from the placement component 211 to the transfer device 40.

[0171] During operation, the transfer device 40 moves the annular stator core 1 into the working area of ​​the loading and unloading device 23. The loading and unloading device 23 picks up the annular stator core 1 from the transfer device 40. At the same time, the placement component 211 moves from the winding position to the loading and unloading position. The loading and unloading device 23 places the picked-up annular stator core 1 on the winding table 2111 of the placement component 211. Then, the placement component 211 moves from the loading and unloading position to the winding position. The limiting and cooperating component 212 moves down and abuts against the annular stator core 1 on the winding table 2111, thus limiting the annular stator core 1. Next, the winding device 22 starts to wind the annular stator core 1. At the same time, the first rotary drive 2112 drives the winding table 2111 to rotate, changing the relative position of the annular stator core 1 and the winding device 22. After the annular stator core 1 completes a full circle of winding to form an annular stator, the limiting table 2122 moves upward and separates from the wound annular stator. The placement component 211 moves from the winding position to the loading and unloading position. The loading and unloading device 23 picks up the annular stator from the winding table 2111 and places it on the transfer device 40. At the same time, the loading and unloading device 23 picks up the annular stator core 1 from the transfer device 40 and places it on the limiting table 2122 to carry out the next set of annular stator core 1 winding operations.

[0172] The above description is merely an exemplary embodiment of the present invention and does not limit the scope of protection of the present invention. Any equivalent structural transformations made based on the technical concept of the present invention and the contents of the specification and drawings of the present invention, or direct / indirect applications in other related technical fields, are included within the scope of protection of the present invention.

Claims

1. A stator winding method, characterized in that, This method is applied to a stator winding production line, which includes a bending machine, a winding machine, and a straightening machine. The stator winding method includes the following steps: The bar stator core is fed to the bending machine, and the bending machine is controlled to bend the bar stator core in the opposite direction to form an annular stator core with the winding part facing outward. The winding machine is controlled to wind the winding section on the outer periphery of the annular stator core to form an annular stator; The straightening machine is controlled to unfold and straighten the annular stator to form a strip stator; The bending machine includes a bending device, which includes a bending component and a bending drive mechanism. The bending component has a strip-shaped state and an annular state. The bending drive mechanism is used to drive the bending component to switch between the strip-shaped state and the annular state. The steps of feeding the strip stator core to the bending machine and controlling the bending machine to bend the strip stator core in the reverse direction to form an annular stator core with the winding portion facing outward include: The bending drive mechanism is controlled to drive the bending component to a strip state, and the strip stator core is positioned on the bending component in the strip state. The bending drive mechanism is controlled to drive the bending component to bend and deform, so as to switch the bending component from the strip state to the ring state, and bend the strip stator core in the opposite direction to form a ring stator core with the winding part facing outward. The bending device further includes a first positioning member and a second positioning member disposed opposite to each other along a first direction. The bending member is used to fit against the side of the first positioning member facing the second positioning member when it is in a strip-shaped state, and to fit against the outer surface of the second positioning member when it is in a ring-shaped state.

2. The stator winding method as described in claim 1, characterized in that, The bending machine also includes a mold-feeding device. Before the step of controlling the winding machine to wind the winding portion on the outer periphery of the annular stator core to form an annular stator, the machine further includes: controlling the mold-feeding device to install the mold onto the annular stator core, shaping the annular stator core, and maintaining the annular stator core in the bent annular state.

3. The stator winding method as described in claim 1, characterized in that, The straightening machine includes a straightening device, which includes a first straightening component and a second straightening component. The step of controlling the straightening machine to unfold and straighten the annular stator into a strip stator includes: The first straightening assembly is controlled to unfold the annular stator into a strip stator; The second straightening assembly is controlled to straighten the unfolded strip stator by maintaining pressure.

4. The stator winding method as described in claim 3, characterized in that, The straightening machine also includes a demolding device, and before the step of controlling the straightening machine to unfold and straighten the annular stator to form a strip stator, the machine further includes: controlling the demolding device to separate the annular stator from the mold.

5. The stator winding method according to any one of claims 1 to 4, characterized in that, The winding machine includes a winding limiting device and a winding device. The step of controlling the winding machine to wind the winding portion on the outer periphery of the annular stator core to form an annular stator includes: The annular stator core is positioned within the winding limiting device; The winding device is controlled to wind the winding section on the outer periphery of the annular stator core, and the winding limiting device is controlled to drive the annular stator core to rotate axially, so that multiple winding sections on the outer periphery of the annular stator core sequentially face the winding device to complete the winding, thereby obtaining an annular stator.

6. A stator winding production line, characterized in that, include: A bending machine, used to bend a strip stator core in the reverse direction to form an annular stator core with the winding portion facing outward; A winding machine, which is used to receive annular stator cores and to wind wires on the annular stator cores to form an annular stator; as well as A straightening machine, used to unfold and straighten an annular stator to form a strip stator; The bending machine includes a bending device, which includes a bending component and a bending drive mechanism. The bending component has a strip-shaped state and an annular state. The bending drive mechanism is used to drive the bending component to switch between the strip-shaped state and the annular state. The bending component is used to position the strip stator core in the strip-shaped state and to bend the strip stator core in the opposite direction to form an annular stator core with the winding portion facing outward during the process of switching from the strip-shaped state to the annular state. The bending device further includes a first positioning member and a second positioning member disposed opposite to each other along a first direction. The bending member is used to fit against the side of the first positioning member facing the second positioning member when it is in a strip-shaped state, and to fit against the outer surface of the second positioning member when it is in a ring-shaped state.

7. The stator winding production line as described in claim 6, characterized in that, The bending drive mechanism includes a bending drive component and two swing arms. The two swing arms are movably connected to both ends of the bending component. The ends of the two swing arms away from the bending component are respectively connected to the bending drive component. The bending drive component is used to drive the two swing arms to expand or close relative to each other, so as to drive the bending component to switch between a strip state and a ring state.

8. The stator winding production line as described in claim 7, characterized in that, The bending drive mechanism further includes a transmission plate that is movably arranged along a first direction. The ends of the two swing arms away from the bending member are respectively hinged to the transmission plate. The bending drive member is used to drive the transmission plate to move along the first direction, so as to drive the two swing arms to spread out or move closer to each other.

9. The stator winding production line as described in claim 6, characterized in that, The bending device further includes a positioning component, which includes a first gripper. The first gripper is used to clamp the two ends of the bending component when the bending component is in an annular state, and to bring the two ends of the bending component closer to each other so that the bending component fits against the peripheral side of the second positioning component.

10. The stator winding production line as described in claim 9, characterized in that, The positioning component further includes a second gripper, which is used to grip the beginning and end ends of the annular stator core when the bent circular part is in an annular state, and to bring the beginning and end ends of the annular stator core closer to each other.

11. The stator winding production line as described in claim 6, characterized in that, The bending component includes multiple chain links that are connected in sequence. Each chain link has a receiving groove, and the multiple receiving grooves are connected in sequence to form a limiting groove. The limiting groove is used to limit the placement of the annular stator core.

12. The stator winding production line as described in claim 6, characterized in that, The bending machine further includes a mold-feeding device, which includes a first clamping member, a second clamping member, and a transfer table. The first clamping member is used to clamp the mold and move the mold to the transfer table. The second clamping member is used to clamp the annular stator core and install the annular stator core onto the mold to shape the annular stator core.

13. The stator winding production line as described in claim 12, characterized in that, The second clamping member includes a rounding drive, a second base, and a plurality of third jaws. The plurality of third jaws are movably disposed on the second base and are used to clamp the outer periphery of the annular stator core. The rounding drive is used to drive the plurality of third jaws to move synchronously along the second base to round the annular stator core.

14. The stator winding production line as described in claim 13, characterized in that, The second clamping member further includes a movable plate, which is rotatably mounted on the second base along the axial direction of the second base. The movable plate has a plurality of adjustment slots spaced apart along the circumference of the second base. Each adjustment slot has a first end near the axis of the second base and a second end away from the axis of the second base. The plurality of adjustment slots are paired with a plurality of third grippers. Each third gripper has a linkage portion movably disposed in the corresponding adjustment slot. The full-circle drive member is used to drive the movable plate to rotate axially, so as to drive the linkage portion of each third gripper to reciprocate between the first end and the second end, thereby causing each third gripper to swing along the second base.

15. The stator winding production line as described in claim 12, characterized in that, The straightening machine includes a demolding device and a straightening device. The demolding device is used to receive an annular stator with the mold and to separate the annular stator from the mold. The straightening device is used to unfold the demolded annular stator to form the strip stator.

16. The stator winding production line as described in claim 15, characterized in that, The straightening device includes a first straightening component and a second straightening component. The first straightening component is used to unfold the annular stator to form a strip stator, and the second straightening component is used to maintain pressure on the strip stator to straighten it.

17. The stator winding production line according to any one of claims 6 to 16, characterized in that, The winding machine includes a winding limiting device and a winding device. The winding limiting device is used to limit the placement of the annular stator core and to drive the annular stator core to rotate axially. The winding device is used to wind wire on the winding portion outside the annular stator core to form an annular stator.

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