Torsion forming tool and torsion forming equipment for stator winding

Abstract

The invention belongs to the technical field of motor assembly, and particularly relates to a torsion forming tool and torsion forming equipment for a stator winding. The first torsion assembly comprises M rotating parts, M is larger than or equal to N, N is larger than or equal to 2 and is an even number, each rotating part comprises a first shaft sleeve and a first supporting plate, the M first shaft sleeves are sequentially arranged in a sleeving mode from inside to outside, and the M first supporting plates are sequentially arranged in a stacked mode from bottom to top; the second torsion assembly comprises N dies which are coaxially arranged, each die comprises a second shaft sleeve and a second supporting plate, each second supporting plate is detachably connected with the corresponding first shaft sleeve, and a plurality of grooves are formed in the end face of each second shaft sleeve; and the output end of each driving assembly is rotationally connected with the first supporting plate of the corresponding rotating part. The hairpin wire twisting device is suitable for twisting hairpin wires of various types and is good in universality, compact in structure, small in occupied space and low in manufacturing cost.

Description

Technical Field

[0001] The present application relates to the technical field of motor assembly, and more particularly, to a torsion forming tool and torsion forming equipment for stator windings. Background Art

[0002] Flat-wire motors, the drive motors for future new energy vehicles, feature stator windings wound with rectangular-cross-sectional conductors. Compared to traditional round-wire motors with circular conductors, these motors can accommodate more conductors within the same stator slot area, thereby increasing power density. As a result, flat-wire motors can accommodate more stator windings within the same volume, resulting in higher power and torque output with the same losses. These motors are particularly well-suited for automotive drive motors requiring miniaturization and lightweighting.

[0003] Hairpins are a common conductor type in the stator windings of flat-wire motors, and stator windings typically have an even number of turns. The manufacturing process for the stator windings involves twisting the ends of the hairpins, inserting multiple turns of hairpins into the multi-layer grooves arranged circumferentially in the stator core. The protruding ends of two adjacent turns of hairpins are then twisted in different directions by a certain angle. The twisting forming equipment used in related technologies is relatively large and can typically only produce hairpins with a fixed number of turns, such as 4 or 8 turns. If the stator winding has more turns of hairpins, a separate set of twisting forming equipment must be designed, which has poor versatility, occupies a large space, and has high production costs. Summary of the Invention

[0004] The purpose of the present application is to provide a twisting forming tool and twisting forming equipment for stator windings, which is suitable for twisting various types of hairpin wires, has good versatility, a compact structure, takes up little space, and has low production cost.

[0005] In the first aspect, an embodiment of the present application provides a torsion forming tool for a stator winding, the stator winding comprising a stator core and N turns of hairpin wires spaced apart along the radial direction of the stator core, N ≥ 2 and being an even number, the torsion forming tool comprising: a base having a first accommodating space and a mounting hole passing through the first accommodating space in a first direction, S partitions spaced apart along the first direction in the first accommodating space to divide the first accommodating space into S+1 accommodating layers, the mounting hole being used to cooperate with the stator core; a first torsion assembly being arranged in the first accommodating space, the first torsion assembly comprising M rotating members coaxially arranged with the mounting hole, and M ≥ N, S = 0.5*M-1, each rotating member comprising a first sleeve and a first support plate arranged at one axial end of the first sleeve, the first sleeves of the M rotating members being sequentially sleeved from the inside out, the first support plates of the M rotating members being sequentially stacked from bottom to top, and the first support plates of two adjacent rotating members being arranged in a a receiving layer; a second torsion component, comprising N coaxially arranged molds, each mold comprising a second sleeve and a second support plate arranged at one axial end of the second sleeve, the second sleeves of the N molds are sequentially sleeved from the inside to the outside, the second support plates of the N molds are sequentially stacked from bottom to top, a second support plate is detachably connected to a corresponding first sleeve, and a plurality of grooves distributed along its own circumferential direction are provided on the end face of the end of each second sleeve away from the second support plate, and the plurality of grooves are used to accommodate the protruding ends of a corresponding circle of hairpin wires; and N driving components, which are arranged at intervals along the outer circumference of the first receiving space, and the output end of each driving component is rotatably connected to the first support plate of a corresponding rotating part, wherein the N driving components can drive the first support plates of their respective rotating parts to rotate simultaneously in a preset direction, so that the second sleeves of their respective corresponding molds drive the protruding ends of the corresponding circle of hairpin wires to twist by preset angles respectively.

[0006] According to an embodiment of the present application, a torsion forming tool for stator windings is provided, which is applied to a stator winding including N turns of hairpin wire. The torsion forming tool includes a base plate, a first torsion assembly, a second torsion assembly, and N drive assemblies. The base has a first accommodation space and a mounting hole that passes through the first accommodation space in a first direction. The first accommodation space is divided into S+1 accommodation layers by S partitions arranged at intervals along the first direction. The first torsion assembly includes M rotating members coaxially arranged with the mounting hole, and M≥N, S=0.5*M-1. Each rotating member includes a first sleeve and a first support plate arranged at one axial end of the first sleeve. The first support plates of two adjacent rotating members are arranged in one accommodation layer. The second torsion assembly includes N coaxial molds. Each mold includes a second sleeve and a second support plate arranged at one axial end of the second sleeve, the second support plate of a mold is detachably connected to the first sleeve of a corresponding rotating member, and the end surface of each second sleeve away from the second support plate is provided with a plurality of grooves spaced along its own circumference, and the plurality of grooves are used to accommodate the protruding ends of a corresponding circle of hairpin wires; N drive assemblies are spaced along the outer circumference of the first accommodating space, and the output end of each drive assembly is rotatably connected to the first support plate of a corresponding rotating member, wherein the N drive assemblies can drive the first support plates of their respective rotating members to rotate simultaneously in a preset direction, so that the second sleeves of their respective corresponding molds drive the protruding ends of the corresponding circles of hairpin wires to twist respectively by a preset angle. Therefore, the twisting forming tool of the present application can be used to twist various types of hairpin wires, for example, the number N of circles of the hairpin wire can be any even number within 2 to 12 circles, and only the number of molds and drive assemblies needs to be adjusted. It has good versatility, a compact structure, small space occupation, and low production cost.

[0007] In addition, the torsion forming tool for stator windings according to the present application may also have the following additional technical features:

[0008] In some embodiments of the present application, the second torsion assembly further includes a plurality of mounting keys and a plurality of first fasteners, the first sleeve is provided with a plurality of first notches spaced apart along its circumference, the second support plate is provided with a plurality of second notches spaced apart along its circumference, the mounting key is provided between the first notch and the second notch, and the first fastener is sequentially passed through the second support plate, the mounting key and the first sleeve.

[0009] In some embodiments of the present application, a support assembly is arranged between the second support plates of two adjacent molds, and the support assembly includes a connecting plate, a fixing member and a follower bearing. The connecting plate is arranged on the side of the second support plate away from the second sleeve, the fixing member is arranged between the connecting plate and the second support plate of the adjacent mold, and the outer peripheral surface of the follower bearing is in contact with the connecting plate.

[0010] In some embodiments of the present application, the second torsion assembly further includes a plug-in assembly, which includes a center rod and a latch, one end of the center rod is passed through the second sleeves of N molds, and the other end of the center rod is connected to the latch.

[0011] In some embodiments of the present application, the base includes a first substrate, a second substrate and a plurality of fixed columns, the first substrate and the second substrate are spaced apart along a first direction, the mounting hole passes through the first substrate and the second substrate, and the plurality of fixed columns are spaced apart between the first substrate and the second substrate along the circumference of the mounting hole, a first accommodation space is formed between the first substrate, the second substrate and the plurality of fixed columns, and each partition is connected to the plurality of fixed columns; in each accommodation layer, a rotary bearing is respectively arranged between the two first support plates and between the first support plate and the adjacent partition or the adjacent first substrate.

[0012] In some embodiments of the present application, the drive assembly includes a drive motor and a reducer, and the drive motors of multiple drive assemblies are arranged at circumferential intervals along the first substrate. The output shaft of the drive motor is connected to the input end of the reducer, and the output end of the reducer is rotatably connected to the first support plate of the rotating member.

[0013] In some embodiments of the present application, the reducer includes a first rotating shaft, a reduction gear arranged on the first rotating shaft, and a gear set meshing with the reduction gear, the two ends of the first rotating shaft are respectively rotatably connected to the first substrate and the second substrate, the outer peripheral surface of the first support plate of each rotating member is provided with a fan-shaped gear portion, and the fan-shaped gear portion is meshed with the reduction gear of the corresponding drive assembly; the base also includes a bottom plate, the bottom plate is located on the side of the first substrate away from the second substrate, and a second accommodating space is formed between the bottom plate and the first substrate, the fixing column extends from the first substrate and is fixed to the bottom plate, the gear set is arranged in the second accommodating space, one gear in the gear set is coaxially connected to the output shaft of the drive motor, and the other gear in the gear set is coaxially connected to the first rotating shaft.

[0014] In some embodiments of the present application, the driving motors of the N driving assemblies are arranged at the same height along the axial direction of the first rotating shaft, and the height between the reduction gears of the N driving assemblies and the first substrate is gradually changed.

[0015] In some embodiments of the present application, the base also includes a third substrate and a plurality of second rotating shafts. The third substrate is located on the side of the second substrate away from the first substrate. The plurality of second rotating shafts are arranged between the second substrate and the third substrate at circumferential intervals along the mounting hole to form a third accommodating space. The mounting hole also passes through the third substrate along the first direction; the first sleeves of the M rotating parts are arranged flush at the end away from their respective first support plates, and the second torsion assembly is located in the third accommodating space.

[0016] In some embodiments of the present application, the base also includes a third rotating shaft and a support frame. The support frame is arranged on the side of the third substrate facing away from the second substrate. The third rotating shaft passes through the first substrate, the second substrate and the support frame. The second rotating shaft also passes through the support frame. The stator core is cooperated with the support frame through a tray tooling.

[0017] In a second aspect, an embodiment of the present application provides a torsion forming device, comprising a frame and a torsion forming tool for stator windings according to each embodiment of the present application, wherein the torsion forming tool is connected to the frame via a base.

[0018] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Various other advantages and benefits will become apparent to those skilled in the art upon reading the detailed description of the preferred embodiment below. The accompanying drawings are for illustration purposes only and are not to be considered as limiting the present application. Throughout the drawings, the same reference numerals are used to denote the same components.

[0020] Various other advantages and benefits will become apparent to those skilled in the art upon reading the detailed description of the preferred embodiment below. The accompanying drawings are for illustration purposes only and are not to be considered as limiting the present application. Throughout the drawings, the same reference numerals are used to denote the same components.

[0021] Figure 1 This is a schematic structural diagram of the stator winding according to an embodiment of the present application;

[0022] Figure 2 This is a schematic diagram of a partially exploded structure of a torsion forming tool according to an embodiment of the present application;

[0023] Figure 3 for Figure 2 The schematic diagram of the structure of the twist forming tooling shown is a top view from above;

[0024] Figure 4 for Figure 3 Cross-section along direction AA;

[0025] Figure 5 Schematic diagram of the enlarged structure of area B in the figure;

[0026] Figure 6 for Figure 2 A schematic structural diagram of the second torsion assembly of the torsion forming tool shown;

[0027] Figure 7 for Figure 6 Cross-section along direction CC;

[0028] Figure 8 for Figure 2 The schematic diagram of the top structure of the twist forming tooling shown is viewed from the bottom up;

[0029] Figure 9 for Figure 8 Cross-section along direction DD;

[0030] Figure 10 for Figure 2 The schematic diagram of the structure of the torsion forming tooling hidden drive motor shown;

[0031] Figure 11 This is a schematic structural diagram of a torsion forming tooling according to an embodiment of the present application;

[0032] Figure 12 for Figure 11 The torsion forming tool is shown in a cross-sectional view along direction EE.

[0033] The reference numerals in the accompanying drawings represent the following:

[0034] 100, twist forming tool; 200, stator winding; 201, stator core; 202, hairpin wire; X, first direction; M, tray tool;

[0035] 1. First torsion assembly; 11. Rotating member; 111. First sleeve; 1111. First notch; 112. First support plate; 113. Sector gear portion; 114. Slewing bearing;

[0036] 2. Second torsion assembly; 21. Mold; 210. Groove; 211. Second sleeve; 212. Second support plate; 2121. Second notch; 213. Support assembly; 2131. Connecting plate; 2132. Fixing member; 2133. Follower bearing;

[0037] 22. Mounting key; a. Mounting hole; b. Countersunk hole; c. Threaded hole; 24. Connector assembly; 241. Center rod; 242. Latch;

[0038] 3. Drive assembly; 31. Drive motor; 32. Reducer; 321. First rotating shaft; 322. Reduction gear; 323. Gear set;

[0039] 4. Base; 40. Mounting hole; 4a. First accommodating space; 4b. Support frame; 41. First substrate; 41a. Accommodating layer; 42. Second substrate; 43. Third substrate; 44. Partition; 45. Fixed column; 46. Bottom plate; 47. Second rotating shaft; 48. Third rotating shaft. DETAILED DESCRIPTION

[0040] The following describes exemplary embodiments of the present application in more detail with reference to the accompanying drawings. Although exemplary embodiments of the present application are shown in the accompanying drawings, it should be understood that the present application can be implemented in various forms and should not be limited by the embodiments described herein. Instead, these embodiments are provided to enable a more thorough understanding of the present application and to fully convey the scope of the present application to those skilled in the art.

[0041] It should be understood that the terms used herein are for the purpose of describing specific example embodiments only and are not intended to be limiting. Unless the context clearly indicates otherwise, the singular forms "one", "an" and "said" as used herein may also be meant to include plural forms. The terms "comprise", "include", "contain" and "have" are inclusive and therefore specify the presence of stated features, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, steps, operations, elements, parts, and / or combinations thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring them to be performed in the specific order described or illustrated, unless the order of execution is clearly indicated. It should also be understood that additional or alternative steps may be used.

[0042] Although the terms first, second, third, etc. can be used in the text to describe multiple elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms can only be used to distinguish an element, component, region, layer or section from another region, layer or section. Unless the context clearly indicates otherwise, terms such as "first", "second" and other numerical terms do not imply order or sequence when used in the text. Therefore, the first element, component, region, layer or section discussed below can be referred to as the second element, component, region, layer or section without departing from the teaching of the example embodiments.

[0043] For ease of description, spatially relative terms may be used herein to describe the relationship of one element or feature relative to another element or feature as shown in the figures, such as "inside," "outside," "inside," "outside," "below," "beneath," "above," and the like. Such spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is flipped, an element described as "below" or "below" another element or feature would then be oriented as "above" or "above" another element or feature. Thus, the example term "below" can include both above and below orientations. The device may be otherwise oriented (rotated 90 degrees or in other orientations) and the spatially relative descriptors used herein are interpreted accordingly.

[0044] References herein to "embodiments" mean that a particular feature, structure, or characteristic described in connection with the embodiments may be included in at least one embodiment of the present application. The appearance of this phrase in various places in the specification does not necessarily refer to the same embodiment, nor does it constitute an independent or alternative embodiment that is mutually exclusive of other embodiments. It is understood, both explicitly and implicitly, by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0045] In the description of the embodiments of the present application, unless otherwise expressly specified or limited, technical terms such as "installed," "connected," "connected," and "fixed" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integration; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; internal connections between two components or interactions between two components. Those skilled in the art can understand the specific meanings of the above terms in the embodiments of the present application based on specific circumstances.

[0046] Figure 1 This is a schematic structural diagram of the stator winding according to an embodiment of the present application.

[0047] like Figure 1As shown, the stator winding 200 of the embodiment of the present application includes a stator core 201 and a multi-turn winding disposed on the stator core 201. Each turn of the winding includes multiple hairpin conductors 202 spaced circumferentially along the stator core 201. Specifically, the stator winding 200 includes a multi-turn winding disposed on the stator core 201. The multiple hairpin conductors 202 of the multi-turn winding are radially aligned, such that the multiple hairpin conductors 202 are spaced radially along the stator core 201. The stator winding 200 typically has an even number of hairpin conductors 202, meaning the number of turns can be any number, such as 2, 4, 6, 8, or 12. For example, the stator winding 200 of this embodiment includes 8 turns of winding. The hairpin conductors 202 may be U-shaped copper wires. Each hairpin conductor 202 has two protruding ends. The multiple hairpin conductors 202 are spaced circumferentially and radially along the stator core 201. It is understandable that the hairpin conductors 202 may also be I-type copper wires, and each hairpin conductor 202 has an extended end.

[0048] The stator winding 200 is applied to a flat wire motor. The manufacturing process of the stator winding 200 mainly includes inserting insulating paper, inserting hairpin wires, twisting the ends of the hairpin wires, cutting the ends, and welding the ends. Figure 1 The stator winding 200 shown in the figure is typically placed on a tray fixture. A twist forming process is then performed on the ends of the hairpin conductors 202 using a twist forming machine. This involves inserting multiple turns of hairpin conductors into the multi-layered grooves arranged circumferentially along the stator core. The extended ends of two adjacent turns of hairpin conductors are then twisted in different directions by a predetermined angle. The twist forming machines used in related art are relatively large and can typically only produce hairpin conductors with a fixed number of turns, such as four or eight. If the stator winding has more turns of hairpin conductors, a separate twist forming machine must be designed, which has limited versatility, occupies a large space, and is costly to manufacture.

[0049] To this end, the purpose of this application is to provide a stator winding twisting forming tool, which is suitable for twisting various types of hairpin wires, has good versatility, a compact structure, occupies little space, and has low production cost.

[0050] Figure 2 This is a schematic diagram of a partially exploded structure of a torsion forming tool according to an embodiment of the present application. Figure 3 for Figure 2 The schematic diagram of the twist forming tooling shown is a top-down structural diagram. Figure 4 for Figure 3 Cross-section along direction AA.

[0051] like Figures 2 to 4As shown, an embodiment of the present application provides a torsion forming tool 100 for a stator winding 200, wherein the stator winding 200 includes a stator core 201 and N turns of hairpin wires 202 radially spaced along the stator core 201, where N is greater than or equal to 2 and is an even number, and the torsion forming tool 100 includes a base 4, a first torsion component 1, a second torsion component 2 and N drive components 3.

[0052] The base 4 has a first accommodating space 4a and a mounting hole 40 that passes through the first accommodating space 4a along the first direction X. S partitions 44 are arranged at intervals along the first direction X in the first accommodating space 4a to divide the first accommodating space 4a into S+1 accommodating layers 41a. The mounting hole 40 is used to cooperate with the stator core 201.

[0053] The first torsion assembly 1 is arranged in the first accommodating space 4a. The first torsion assembly 1 includes M rotating parts 11 coaxially arranged with the mounting hole 40, and M≥N, S=0.5*M-1. Each rotating part 11 includes a first sleeve 111 and a first support plate 112 arranged at one axial end of the first sleeve 111. The first sleeves 111 of the M rotating parts 11 are sequentially sleeved from the inside to the outside, and the first support plates 112 of the M rotating parts 11 are sequentially stacked from bottom to top. The first support plates 112 of two adjacent rotating parts 11 are arranged in an accommodating layer 41a.

[0054] The second torsion assembly 2 includes N coaxially arranged molds 21, each mold 21 includes a second sleeve 211 and a second support plate 212 arranged at one axial end of the second sleeve 211, the second sleeves 211 of the N molds 21 are sequentially sleeved from the inside to the outside, and the second support plates 212 of the N molds 21 are stacked sequentially from bottom to top, one second support plate 212 is connected to a corresponding first sleeve 111, and a plurality of grooves 210 are provided on the end face of the end away from the second support plate 212, which are distributed along the circumference of the second sleeve 211, and the plurality of grooves 210 are used to accommodate the protruding ends of a corresponding circle of hairpin wires 202.

[0055] N drive assemblies 3 are arranged at intervals along the outer periphery of the first accommodating space 4a, and the output end of each drive assembly 3 is rotatably connected to the first support plate 112 of a corresponding rotating member 11, wherein the N drive assemblies 3 can drive the first support plates 112 of their respective rotating members 11 to rotate simultaneously in a preset direction, so that the second sleeves 211 of the respective corresponding molds 21 drive the protruding ends of the corresponding circle of hairpin wires 202 to twist by preset angles respectively.

[0056] For ease of description, this embodiment of the present application uses N=4 and M=12 as an example. Specifically, the stator winding 200 includes a stator core 201 and four turns of hairpin wire 202 spaced radially along the stator core 201. The first torsion assembly 1 includes at least 12 rotating members 11 coaxially disposed with the mounting hole 40. The second torsion assembly 2 includes four coaxially disposed molds 21. Four drive assemblies 3 are spaced along the periphery of the first accommodating space 4a of the base 4. The four drive assemblies 3 are capable of driving the first support plates 112 of their respective rotating members 11 to rotate simultaneously in a predetermined direction, causing the second sleeves 211 of their respective molds 21 to rotate the protruding ends of the corresponding turns of hairpin wire 202 by a predetermined angle. The protruding ends of two adjacent turns of hairpin wire 202 are twisted in different directions by predetermined angles. The magnitude of the predetermined angles depends on the specific type and size of the stator winding 200 and will not be further described.

[0057] More specifically, each rotating member 11 includes a first sleeve 111 and a first support plate 112 disposed at one axial end of the first sleeve 111. The first sleeves 111 of the twelve rotating members 11 are sequentially arranged from the inside out, and the first support plates 112 of the twelve rotating members 11 are stacked from bottom to top. That is, the first first sleeve 111 corresponding to the first coil of hairpin wires 202 is located at the innermost side, the second first sleeve 111 corresponding to the second coil of hairpin wires 202 is mounted on the outer circumference of the first first sleeve 111, and so on. Accordingly, the first first support plate 112 corresponding to the first coil of hairpin wires 202 is located at the bottommost side, the second first support plate 112 corresponding to the second coil of hairpin wires 202 is stacked above the first first support plate 112, and so on. The end surfaces of the twelve first sleeves 111 on the side away from the first support plate 112 can be arranged to increase in height from the inside out, or they can be arranged at the same height.

[0058] Each mold 21 includes a second sleeve 211 and a second support plate 212 disposed at one axial end of the second sleeve 211. The second sleeves 211 of the four molds 21 are sequentially mounted from the inside out, and the second support plates 212 of the four molds 21 are stacked from bottom to top. That is, the first second sleeve 211 corresponding to the first circle of hairpin wires 202 is located at the innermost side, the second second sleeve 211 corresponding to the second circle of hairpin wires 202 is mounted on the outer circumference of the first second sleeve 211, and so on. Accordingly, the first second support plate 212 corresponding to the first circle of hairpin wires 202 is located at the bottommost side, the second second support plate 212 corresponding to the second circle of hairpin wires 202 is stacked above the first second support plate 212, and so on. Among them, each second support plate 212 is connected to a corresponding first sleeve 111, so that the second torsion component 2 and the first torsion component 1 are connected to each other, and under the action of the four driving components 3, the protruding ends of the four turns of the hairpin wire 202 of the stator winding 200 are driven to twist the preset angles respectively.

[0059] In addition, five partitions 44 are spaced apart along the first direction X within the first receiving space 4a of the base 4, dividing the first receiving space 4a into six receiving levels 41a. Each receiving level 41a houses two first support plates 112 of two rotating members 11, allowing the extended ends of two adjacent turns of hairpin wire 202 to be twisted in different directions and by predetermined angles. A second support plate 212 of each mold 21 is connected to the first sleeve 111 of a corresponding rotating member 11. The output end of each drive assembly 3 is rotationally connected to the first support plate 112 of a corresponding rotating member 11. The rotation direction and angle of each drive assembly 3 are determined based on the twist direction and angle of the extended ends of each turn of hairpin wire 202. This allows each drive assembly 3 to drive a rotating member 11 and a corresponding mold 21 to rotate together, thereby completing the twist forming process for the extended ends of four turns of hairpin wire 202. Furthermore, the twist forming tool 100 has a compact structure, occupies little space, and has low manufacturing costs.

[0060] It is understood that the stator winding twisting tool 100 of the present embodiment can be used to twist various types of hairpin conductors 202, for example, M = 12, where N is any even number between 2 and 12. Because a second support plate 212 of each mold 21 is detachably connected to a corresponding first sleeve 111 of a rotating member 11, the number N of molds 21 and the number N of drive assemblies 3 can be freely switched according to the number N of turns of the hairpin conductor 202, while the number M of rotating members 11 can remain unchanged, thereby improving the versatility of the twisting tool 100.

[0061] Figure 5 This is a schematic diagram of the enlarged structure of area B in the figure.

[0062] In some embodiments, the second torsion assembly 2 also includes a plurality of installation keys 22 and a plurality of first fasteners (not shown in the figure), the first sleeve 111 is provided with a plurality of first notches 1111 at intervals along its own circumference, the second support plate 212 is provided with a plurality of second notches 2121 at intervals along its own circumference, the installation key 22 is provided between the first notch 1111 and the second notch 2121, and the first fastener is sequentially passed through the second support plate 212, the installation key 22 and the first sleeve 111.

[0063] like Figure 5 As shown, the mounting key 22 can be a flat key, and the mounting key 22 is provided with a mounting hole a that penetrates its own thickness. A countersunk hole b can be correspondingly provided on the side of the second support plate 212 away from the second notch 2121, and a threaded hole c is provided on the bottom surface of the first notch 1111 of the first sleeve 111. The mounting key 22 is provided between the first notch 1111 of the first sleeve 111 and the second notch 2121 of the second support plate 212, and is used to limit the relative rotation between the first sleeve 111 and the second support plate 212; the first fastener is sequentially passed through the countersunk hole of the second support plate 212 and the mounting hole of the mounting key 22, and is connected to the threaded hole of the first sleeve 111, further limiting the relative rotation between the first sleeve 111 and the second support plate 212, and at the same time limiting the relative movement between the first sleeve 111 and the second support plate 212, further improving the connection strength between the first sleeve 111 and the second support plate 212, and reducing the possibility of connection failure between the first torsion assembly 1 and the second torsion assembly 2. At the same time, the threaded connection method of the first fastener and the connection method of the installation key 22 facilitate the disassembly of the first torsion component 1 and the second torsion component 2, so that different numbers of molds 21 and drive components 3 can be freely switched according to the number of turns of the hairpin wire 202, thereby improving the versatility of the torsion forming tooling 100.

[0064] Figure 6 for Figure 2 The schematic structural diagram of the second torsion assembly of the torsion forming tool shown in FIG. Figure 7 for Figure 6 Cross-section along direction CC.

[0065] In some embodiments, a support assembly 213 is arranged between the second support plates 212 of two adjacent molds 21. The support assembly 213 includes a connecting plate 2131, a fixing member 2132 and a follower bearing 2133. The connecting plate 2131 is arranged on the side of the second support plate 212 away from the second sleeve 211. The fixing member 2132 is arranged between the connecting plate 2131 and the second support plate 212 of the adjacent mold 21, and the outer peripheral surface of the follower bearing 2133 is in contact with the connecting plate 2131.

[0066] like Figure 6 and Figure 7As shown, since the starting and final angles of each of the N turns of hairpin wire 202 may differ, resulting in different rotational speeds for each turn of hairpin wire 202, each drive assembly 3 corresponding to one mold 21 and one rotating member 11 can rotate independently. To this end, in this embodiment, a support assembly 213 is disposed between the two second support plates 212 of two adjacent molds 21. Optionally, this support assembly 213 is a cam follower bearing. The support assembly 213 includes a connecting plate 2131, a fixing member 2132, and a follower bearing 2133. The connecting plate 2131 is connected to the second support plate 212 via fasteners. The fixing member 2132 may be a thin-walled, annular member positioned between the connecting plate 2131 and the second support plate 212 of the adjacent mold 21. The fixing member 2132 is not connected to the connecting plate 2131 or the second support plate 212. The fixing member 2132 is connected to the adjacent second support plate 212 solely under the force of its own gravity, while having a clearance fit with the connecting plate 2131. The outer circumference of the follower bearing 2133 contacts the surface of the connecting plate 2131, enabling each mold 21 to rotate independently. The connecting plate 2131 prevents axial deflection between the two adjacent second support plates 212, enhancing the operational independence of the two adjacent molds 21. It also prevents the follower bearing 2133 from scratching the second support plate 212.

[0067] In some embodiments, the second torsion assembly 2 also includes a plug-in assembly 24, which includes a center rod 241 and a pin 242. One end of the center rod 241 is passed through the second sleeve 211 of N molds, and the other end of the center rod 241 is connected to the pin 242.

[0068] like Figure 7 As shown, the second sleeves 211 of the four molds are each provided with a mounting slot along their radial direction. One end of the center rod 241 of the plug assembly 24 passes through the mounting slot, and the other end of the center rod 241 is connected to the latch 242. The number of mounting slots and plug assemblies 24 can be at least two, and at least two mounting slots are spaced apart along the circumference of the second sleeves 211 of the four molds. The plug assemblies 24 ensure that when the product model of the stator winding 200 is changed, the installation angle of the second sleeves 211 of N molds remains consistent, thereby allowing the multi-turn hairpin wire 202 to deflect according to the preset angle, improving the reliability of the torsion forming tool 100.

[0069] Figure 8 for Figure 2 The top view of the twist forming tooling shown is from the bottom up. Figure 9 for Figure 8 Cross-section along direction DD.

[0070] In some embodiments, the base 4 includes a first substrate 41, a second substrate 42 and a plurality of fixing columns 45. The first substrate 41 and the second substrate 42 are spaced apart along the first direction X. The mounting hole 40 passes through the first substrate 41 and the second substrate 42. The plurality of fixing columns 45 are spaced apart between the first substrate 41 and the second substrate 42 along the circumference of the mounting hole 40. A first accommodating space 4a is formed between the first substrate 41, the second substrate 42 and the plurality of fixing columns 45. Each partition 44 is connected to the plurality of fixing columns 45. In each accommodating layer 41a, a slewing bearing 114 is respectively arranged between the two first support plates 112 and between the first support plate 112 and the adjacent partition 44 or the adjacent first substrate 41.

[0071] like Figure 8 and Figure 9 As shown, a first accommodating space 4a is formed between the first substrate 41, the second substrate 42 and the four fixing pillars 45, and five partitions 44 are arranged at intervals along the first direction X to separate the first accommodating space 4a into six accommodating layers 41a, and each partition 44 is connected to four fixing pillars 45. As mentioned above, a mold 21 and a rotating member 11 corresponding to each driving component 3 can rotate independently. To this end, in this embodiment, each accommodating layer 41a accommodates two first support plates 112 of two rotating members 11, wherein, from bottom to top, in the first accommodating layer 41a at the bottom, a rotary bearing 114 is respectively provided between the two first support plates 112 and between the first support plate 112 and the adjacent first substrate 41; in each accommodating layer 41a from the second accommodating layer 41a to the sixth accommodating layer 41a, a rotary bearing 114 is respectively provided between the two first support plates 112 and between the first support plate 112 and the adjacent partition 44, so that each rotating member 11 can rotate independently, so that each corresponding circle of hairpin wire 202 rotates at a preset speed and is twisted and formed according to its respective starting angle and final angle.

[0072] In some embodiments, the drive assembly 3 includes a drive motor 31 and a reducer 32. The drive motors 31 of multiple drive assemblies 3 are arranged at circumferential intervals along the first substrate 41. The output shaft of the drive motor 31 is connected to the input end of the reducer 32, and the output end of the reducer 32 is rotatably connected to the first support plate 112 of the rotating member 11.

[0073] like Figure 2As shown, four drive motors 31 are spaced apart along the circumference of the first base plate 41. The output shafts of the drive motors 31 are connected to the input of a reducer 32, which in turn is rotatably connected to the first support plate 112 of the rotating member 11. The reducer 32 may be, for example, but not limited to, a gear assembly, a pulley assembly, or a sprocket assembly. Thus, the four drive motors 31, through the torque reduction and torque increase of their respective reducers 32, drive the corresponding first support plate 112 of the rotating member 11 to rotate. Furthermore, through the connection between the first sleeve 111 and the second support plate 212, the protruding ends of the corresponding loops of hairpin wire 202 on the second sleeve 211 are twisted by a predetermined angle, resulting in a compact structure and minimal space consumption.

[0074] In some embodiments, the reducer 32 includes a first rotating shaft 321, a reduction gear 322 arranged on the first rotating shaft 321, and a gear set 323 meshing with the reduction gear 322. The two ends of the first rotating shaft 321 are respectively rotatably connected to the first base plate 41 and the second base plate 42. The outer peripheral surface of the first support plate 112 of each rotating member 11 is provided with a fan-shaped gear portion 113, which meshes with the reduction gear 322 of the corresponding driving assembly 3; the base 4 also includes a bottom plate 46, which is located on the side of the first base plate 41 away from the second base plate 42, and a second accommodating space 4b is formed between the bottom plate 46 and the first base plate 41. The fixing column 45 extends from the first base plate 41 and is fixed to the bottom plate 46. The gear set 323 is arranged in the second accommodating space 4b. One gear in the gear set 323 is coaxially connected to the output shaft of the driving motor 31, and the other gear in the gear set 323 is coaxially connected to the first rotating shaft 321.

[0075] like Figure 8 and Figure 9 As shown, the reducer 32 includes a first rotating shaft 321, a reduction gear 322 mounted on the first rotating shaft 321, and a gear set 323 meshing with the reduction gear 322. A sector gear portion 113 is provided on the outer circumference of the first support plate 112 of each rotating member 11. The sector gear portion 113 meshes with the corresponding reduction gear 322 of the reducer 32, enabling the drive motor 31 to simultaneously rotate the first support plate 112, the first sleeve 111, the second support plate 212, the second sleeve 211, and the corresponding coil of hairpin wire 202. The number of teeth on the sector gear portion 113 is related to the rotation angle of the corresponding coil of hairpin wire 202 and is determined based on the specific application scenario.

[0076] In addition, the base 4 also includes a bottom plate 46, which is located on the side of the first substrate 41 away from the second substrate 42, and a second accommodating space 4b is formed between the bottom plate 46 and the first substrate 41. The gear set 323 is arranged in the second accommodating space 4b, further making the structure of the torsion forming tooling 100 more compact and reducing the overall occupied space.

[0077] Figure 10 for Figure 2 The schematic diagram of the structure of the torsion forming tooling hidden drive motor is shown.

[0078] In some embodiments, the driving motors 31 of the N driving assemblies 3 are arranged at the same height along the axial direction of the first rotating shaft 321 , and the height between the reduction gears 322 of the N driving assemblies 3 and the first substrate 41 is arranged to be gradually changed.

[0079] like Figure 2 、 Figure 4 and Figure 10 As shown, N=4, the four drive motors 31 are arranged at the same height along the axial direction of the first rotating shaft 321, the height between the four reduction gears 322 and the first substrate 41 gradually increases or decreases, and the four reduction gears 322 are arranged at uneven positions along the axial direction of the first rotating shaft 321. Compared with the solution in the related art of arranging N drive motors 31 at uneven heights along the axial direction of the first rotating shaft 321, this embodiment can reduce the overall space occupied by the torsion forming tool 100 along the height direction, further make the structure of the torsion forming tool 100 more compact, reduce the overall space occupied, and save production costs.

[0080] Figure 11 This is a schematic structural diagram of a torsion forming tooling according to an embodiment of the present application. Figure 12 for Figure 11 The torsion forming tool is shown in a cross-sectional view along direction EE.

[0081] In some embodiments, the base 4 also includes a third substrate 43 and a plurality of second rotating shafts 47. The third substrate 43 is located on the side of the second substrate 42 away from the first substrate 41. The plurality of second rotating shafts 47 are arranged between the second substrate 42 and the third substrate 43 at circumferential intervals along the mounting hole 40 to form a third accommodating space 4c. The mounting hole 40 also penetrates the third substrate 43 along the first direction X. The first sleeves 111 of the M rotating parts 11 are arranged flush at one end away from their respective first support plates 112, and the second torsion assembly 2 is located in the third accommodating space 4c.

[0082] like Figure 11 and Figure 12As shown, a third accommodating space 4c is formed between the second base plate 42, the third base plate 43, and the plurality of second rotating shafts 47. The first sleeves 111 of the twelve rotating members 11 are flushly positioned at the ends away from their respective first support plates 112. The second torsion assembly 2 is located in the third accommodating space 4c. Specifically, within the third accommodating space 4c, the second sleeves 211 of the four molds 21 are sequentially positioned from the inside out. The second support plates 212 of the N molds 21 are stacked from bottom to top, with the outer diameter of the lower second support plate 212 being smaller than that of the upper second support plate 212. Each second support plate 212 is detachably connected to its corresponding first sleeve 111. Because the first sleeves 111 of the twelve rotating members 11 are flushly positioned at the ends away from their respective first support plates 112, the dimensions of each second support plate 212 can be very small, thereby simplifying the structure of the second torsion assembly 2, reducing the overall weight of the torsion forming tool 100, and making it easier to switch between different stator windings 200, resulting in lower manufacturing costs.

[0083] In some embodiments, the base 4 also includes a third rotating shaft 48 and a support frame 41b. The support frame 41b is arranged on the side of the third substrate 43 away from the second substrate 42. The third rotating shaft 48 passes through the first substrate 41, the second substrate 42 and the support frame 41b. The second rotating shaft 47 also passes through the support frame 41b. The stator core 201 is matched with the support frame 41b through the tray tooling M.

[0084] like Figure 11 and Figure 12 As shown, there are two third rotating shafts 48 and two support frames 41b respectively. The support frame 41b is arranged on the side of the third substrate 43 away from the second substrate 42. The two third rotating shafts 48 are spaced apart and penetrate the first substrate 41, the second substrate 42 and the support frame 41b. Multiple second rotating shafts 47 also penetrate the support frame 41b. The second rotating shafts 47 and the third rotating shafts 48 are used to improve the structural strength and rigidity of the support frame 41b, so that the support frame 41b can be used to support the tray tooling M. The tray tooling M is used to fix the stator core 201, so as to facilitate the insertion of N turns of hairpin wires 202 into the multiple grooves 210 on the end face of the N second sleeves 211 away from the second support plate 212, and perform the subsequent torsion forming process.

[0085] In addition, an embodiment of the present application further provides a torsion forming device, including a frame and a torsion forming tool 100 for stator windings according to an embodiment of the present application, wherein the torsion forming tool 100 is connected to the frame via a base 4 .

[0086] According to the torsion forming device provided by the embodiment of the present application, including the torsion forming tool 100 for stator winding of the embodiment of the present application, it can be applied to the stator winding 200 including N turns of hairpin wire 202, the torsion forming tool 100 includes a base 4, a first torsion component 1, a second torsion component 2 and N drive components 3, the base 4 has a first accommodating space 4a and a mounting hole 40 passing through the first accommodating space 4a along the first direction X, the first accommodating space 4a is divided into S+1 accommodating layers 41a by S partitions 44 arranged at intervals along the first direction X, the first torsion component 1 includes M rotating parts 11 arranged coaxially with the mounting hole 40, and M≥N, S=0.5*M-1, each rotating part 11 includes a first sleeve 111 and a first support plate 112 arranged at one axial end of the first sleeve 111, the first support plates 112 of two adjacent rotating parts 11 are arranged in one accommodating layer 41a, the second torsion component 2 includes the same N molds 21 are arranged on the axis, each mold 21 includes a second sleeve 211 and a second support plate 212 arranged at one axial end of the second sleeve 211, the second support plate 212 of a mold 21 is connected to the first sleeve 111 of the corresponding rotating part 11, and a plurality of grooves 210 are distributed along its own circumferential direction on the end face of each second sleeve 211 away from the second support plate 212, and the plurality of grooves 210 are used to accommodate the protruding ends of a corresponding circle of hairpin wires 202; N drive components 3 are arranged at intervals along the outer periphery of the first accommodating space 4a, and the output end of each drive component 3 is rotatably connected to the first support plate 112 of the corresponding rotating part 11, wherein the N drive components 3 can drive the first support plates 112 of their respective rotating parts 11 to rotate simultaneously in a preset direction, so that the second sleeves 211 of their respective corresponding molds 21 drive the protruding ends of the corresponding circle of hairpin wires 202 to twist by preset angles respectively. Therefore, the twisting forming tool 100 of the present application can be used to twist various types of hairpin wires 202. For example, the number of turns of the hairpin wire 202 can be any even number within 2 to 12 turns. It only needs to adjust the number of molds 21 and drive components 3. It has good versatility, compact structure, small space occupation, and low production cost.

[0087] The above description is merely a preferred embodiment of the present application, but the scope of protection of the present application is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in the present application should be included in the scope of protection of the present application. Therefore, the scope of protection of the present application should be based on the scope of protection of the claims.

Claims

1. A torsion forming tool for a stator winding, wherein the stator winding comprises a stator core and N turns of hairpin wire spaced apart along the radial direction of the stator core, where N is an even number and is greater than or equal to 2, characterized in that: The torsion forming tool comprises: A base having a first accommodation space and a mounting hole extending through the first accommodation space along a first direction, wherein S partitions are arranged in the first accommodation space at intervals along the first direction to divide the first accommodation space into S+1 accommodation layers, and the mounting hole is configured to cooperate with the stator core; a first torsion assembly disposed in the first accommodation space, the first torsion assembly comprising M rotating members coaxially disposed with the mounting hole, where M ≥ N and S = 0.5*M-1, each rotating member comprising a first sleeve and a first support plate disposed at one axial end of the first sleeve, the first sleeves of the M rotating members being sequentially sleeved from the inside out, the first support plates of the M rotating members being stacked sequentially from bottom to top, and the first support plates of two adjacent rotating members being disposed within one accommodation layer; a second torsion assembly comprising N coaxially arranged molds, each of the molds comprising a second sleeve and a second support plate disposed at one axial end of the second sleeve, the second sleeves of the N molds being sequentially sleeved from the inside out, the second support plates of the N molds being stacked sequentially from bottom to top, each second support plate being detachably connected to a corresponding first sleeve, a plurality of grooves spaced apart along the circumference of each second sleeve being disposed on an end surface away from the second support plate, the plurality of grooves being configured to accommodate the protruding ends of a corresponding ring of hairpin wires; and N drive assemblies are arranged at intervals along the outer periphery of the first accommodating space, and the output end of each drive assembly is rotatably connected to the first support plate of the corresponding rotating member, wherein the N drive assemblies can drive the first support plates of their respective rotating members to rotate simultaneously in a preset direction, so that the second bushings of the corresponding molds drive the protruding ends of the corresponding circle of the hairpin wires to twist by preset angles respectively.

2. The torsion forming tool for stator winding according to claim 1, characterized in that: The second torsion assembly also includes a plurality of installation keys and a plurality of first fasteners. The first sleeve is provided with a plurality of first notches at intervals along its circumference. The second support plate is provided with a plurality of second notches at intervals along its circumference. The installation key is provided between the first notch and the second notch. The first fastener is sequentially passed through the second support plate, the installation key and the first sleeve.

3. The torsion forming tool for stator winding according to claim 1, characterized in that: A support assembly is provided between the second support plates of two adjacent molds, and the support assembly includes a connecting plate, a fixing part and a follower bearing. The connecting plate is provided on the side of the second support plate facing away from the second sleeve, the fixing part is provided between the connecting plate and the second support plate of the adjacent mold, and the outer peripheral surface of the follower bearing is in contact with the connecting plate.

4. The torsion forming tool for stator winding according to claim 1, characterized in that: The second torsion assembly further includes a plug-in assembly, which includes a center rod and a latch, one end of the center rod is passed through N second sleeves of the mold, and the other end of the center rod is connected to the latch.

5. The torsion forming tool for stator winding according to any one of claims 1 to 4, characterized in that: The base includes a first substrate, a second substrate, and a plurality of fixing pillars, wherein the first substrate and the second substrate are spaced apart along the first direction, the mounting hole passes through the first substrate and the second substrate, and the plurality of fixing pillars are spaced apart along the circumference of the mounting hole between the first substrate and the second substrate, and the first accommodation space is formed between the first substrate, the second substrate, and the plurality of fixing pillars, and each of the partitions is connected to the plurality of fixing pillars; In each of the accommodating layers, a rotary bearing is respectively provided between the two first support plates and between the first support plate and the adjacent partition plate or the adjacent first base plate.

6. The torsion forming tool for stator winding according to claim 5, characterized in that: The driving assembly includes a driving motor and a reducer. The driving motors of the multiple driving assemblies are arranged at intervals along the circumference of the first substrate. The output shaft of the driving motor is connected to the input end of the reducer, and the output end of the reducer is rotatably connected to the first support plate of the rotating member.

7. The torsion forming tool for stator winding according to claim 6, characterized in that: The reducer includes a first rotating shaft, a reduction gear provided on the first rotating shaft, and a gear set meshing with the reduction gear, wherein both ends of the first rotating shaft are rotatably connected to the first base plate and the second base plate respectively, and a sector gear portion is provided on the outer peripheral surface of the first support plate of each rotating member, and the sector gear portion meshes with the reduction gear of the corresponding driving assembly; The base also includes a bottom plate, which is located on a side of the first substrate facing away from the second substrate, and a second accommodating space is formed between the bottom plate and the first substrate. The fixing column extends from the first substrate and is fixed to the bottom plate. The gear set is arranged in the second accommodating space, one gear in the gear set is coaxially connected to the output shaft of the drive motor, and the other gear in the gear set is coaxially connected to the first rotating shaft.

8. The torsion forming tool for stator winding according to claim 7, characterized in that: The driving motors of the N driving assemblies are arranged at the same height along the axial direction of the first rotating shaft, and the height between the reduction gears of the N driving assemblies and the first substrate is arranged to be gradually changed.

9. The torsion forming tool for stator winding according to claim 5, characterized in that: The base further includes a third substrate and a plurality of second rotating shafts, the third substrate being located on a side of the second substrate facing away from the first substrate, the plurality of second rotating shafts being spaced apart along the circumference of the mounting hole between the second substrate and the third substrate to form a third accommodation space, and the mounting hole also passes through the third substrate along the first direction; The first bushings of the M rotating members are flushly arranged at one end away from their respective first support plates, and the second torsion assembly is located in the third accommodating space.

10. The torsion forming tool for stator winding according to claim 9, characterized in that: The base also includes a third rotating shaft and a support frame. The support frame is arranged on the side of the third substrate facing away from the second substrate. The third rotating shaft passes through the first substrate, the second substrate and the support plate. The second rotating shaft also passes through the support frame. The stator core is matched with the support frame through a tray tooling.

11. A twist forming device, characterized in that: It comprises a frame and a torsion forming tool for stator winding according to any one of claims 1 to 10, wherein the torsion forming tool is connected to the frame via a base.

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