Flexible flat wire stator flaring device and flaring method

Abstract

The invention relates to the technical field of motor production and processing, in particular to a flexible flat wire stator flaring device and flaring method. Comprising a base, a storage structure, a carrying structure, a fixing structure and a flaring structure are arranged on the base, and the storage structure is used for storing a to-be-flaring stator and a flaring stator; the carrying structure is used for transferring the to-be-flaring stator on the storage structure to the flaring station or transferring the flaring stator on the flaring station to the storage structure; the fixing structure is arranged at the flaring station and used for fixing the root part, extending out of the stator, of the flat wire in the radial direction; when the flat wire penetrates through the fixing structure, the flaring structure is connected to the lower end of the flat wire in a sleeving mode and drives the lower end of the flat wire to move in the radial direction to achieve flaring operation of the flat wire. The flexible flat wire stator flaring device is simple in structure, flaring operation of stator assemblies of various specifications and models can be achieved, the flat wire flaring effect is extremely good, and the machining quality of the stator assemblies is greatly improved.

Description

Technical Field

[0001] This invention relates to the field of motor manufacturing and processing technology, specifically to a flexible flat wire stator flaring device and flaring method. Background Technology

[0002] In motors, there is a type that uses internal coil windings made of flat wires, commonly known as flat wire motors or flat wire stators. The processing flow of the stator of the flat wire motor is to fold the wires with a certain length at both ends and the insulation varnish removed into a "U" shape and insert them into the stator slot. Then, the parts of the different "U" shaped wires with the insulation varnish removed are welded in sequence to form a closed circuit. As the number of flat wire layers in the flat wire stator increases, the flat wires inserted into the stator slots (i.e., in the same radial direction) are tightly packed together. They must be separated in pairs before twisting. The wires at the welding ends need to be spaced a certain distance apart to meet the requirements of subsequent twisting and TIG welding (or laser welding) processes. When separating them, wires in the same radial direction need to be separated into two groups. For example, when producing 8-layer flat wire (defining layers 1 to 8 from the inside out), layers 1 and 2 need to be welded together to form one group, layers 3 and 4 need to be welded together to form one group, layers 5 and 6 need to be welded together to form one group, and layers 7 and 8 need to be welded together to form one group. This process of pulling apart the conductor of the flat wire stator is called flaring. During the flaring process, two bending points are formed. The bending point closer to the stator body is called the flaring start point, and the other bending point is called the closing point. As a core component of new energy vehicles, the performance of the motor directly affects the overall performance of the new energy vehicle. Therefore, the flat wire motor market not only has a large demand, but also has relatively high requirements for the process. Currently, there are two main types of automated equipment for the flaring process: The first type uses automated equipment to insert a flaring die into the end of the "U"-shaped conductor to flare the stator. While this method improves efficiency, it also has significant drawbacks. Because the conductor end is cut, the gap between each set of conductor ends is relatively small. During the insertion of the flaring die, the die exerts an axial force on the conductor. Under this axial force, the conductor is easily pushed out of the stator slot, a phenomenon commonly known as wire slippage. More seriously, the flaring die directly presses against the end of the conductor, making it impossible to insert into the gap between two conductors, thus causing damage or even destruction to the stator. Furthermore, using a flaring die requires a matching closing die to ensure that the axial direction of the conductor does not change. Therefore, the method using a flaring die not only has obvious problems but is also structurally complex. The second method utilizes a combination of motion shafts to drive pneumatic grippers, such as the prior art entitled "A Flat Wire Motor Stator Copper Wire Flaring Device." This prior art proposes a flaring device comprising: a rotary positioning table assembly and a flaring device assembly. The rotary positioning table assembly is used to mount the flat wire stator to be flared and to rotate the flat wire stator. The flaring device assembly is located on one side of the rotary positioning table assembly. This flaring device assembly includes: guide grippers, a flaring die, and a cylinder assembly. The guide grippers are used to clamp individual copper wires. The flaring die is located above the guide grippers and corresponds one-to-one with them, also used to clamp individual copper wires. When the guide grippers and flaring die are clamping the copper wire, the flaring die is pulled away from the center of the flat wire stator to achieve outward bending of the copper wire. The cylinder assembly is connected to the guide grippers and flaring die, and is used to drive the guide grippers and flaring die to move up and down and to move the copper wire away from or towards the flat wire stator. This flaring device can prevent copper wire displacement and deformation. However, this device uses guide jaws and flaring molds to clamp copper wires, and can only clamp and flare a single copper wire at a time, resulting in extremely low flaring efficiency. At the same time, the clamping operation using guide jaws and flaring molds also has the problem of wire slippage.

[0003] It is evident that existing flat wire stator flaring equipment has many problems, and there is an urgent need for a device and method that can efficiently flare flat wire stators. Summary of the Invention

[0004] The purpose of this application is to address the shortcomings of the aforementioned background technology and provide a flexible flat wire stator flaring device and flaring method.

[0005] The technical solution of this application is: a flexible flat wire stator flaring device, comprising a base, characterized in that: the base is provided with, A storage structure for storing the stator to be flared and the stator after flaring; A transport structure is used to transfer a stator to be flared from a storage structure to a flaring station or to transfer a stator that has been flared from a flaring station to a storage structure. A fixing structure is provided at the flaring station to fix the root of the flat wire extending from the stator radially. A flaring structure is located below a fixed structure; the flaring structure includes a plurality of flaring blades arranged circumferentially at intervals, which are sleeved on the lower end of the flat wire when the flat wire passes through the fixed structure; the flaring blades are block-shaped structures that can move circumferentially and radially.

[0006] According to the flexible flat wire stator flaring device provided in this application, the fixing structure includes a bracket fixed on a base; and further includes... A stator fixing structure, comprising a vertically movable fixing column; the fixing column is vertically inserted from bottom to top inside the stator to restrict non-axial movement of the stator; A flat wire fixing structure includes a base plate mounted on a bracket; the base plate has a through hole for a fixing post to pass through, and multiple clamping blocks are arranged around the through hole on the base plate; the clamping blocks are arranged radially, one end of which is connected to the base plate through a drive structure for telescopic movement, and the other end abuts against the outermost flat wire of the stator when the stator is placed on the base plate at the flaring position, so that multiple flat wires in the same slot are clamped and fixed between the clamping block and the fixing post.

[0007] According to the flexible flat wire stator flaring device provided in this application, the driving structure includes a driving ring connected to a base plate that can rotate around an axis and a telescopic cylinder for driving the drive to rotate around the axis; the driving ring has driving grooves that correspond one-to-one with the clamping blocks; the driving groove is an oblique groove that intersects the radial direction but does not coincide, and a pin is provided in the driving groove with one end slidably connected to the driving groove; the other end of the pin is connected to the end of the clamping block away from the fixed post.

[0008] According to the flexible flat wire stator flaring device provided in this application, the flaring structure includes, A flaring tool holder, which is vertically and vertically mounted on a base; A flaring base, which is rotatably connected to a flaring tool holder about a vertical axis; One end of the flaring knife is connected to the flaring chassis and can be moved radially through an adjustment structure, while the other end has multiple slots for engaging the ends of flat wires.

[0009] According to the flexible flat wire stator flaring device provided in this application, the adjustment structure includes... A flaring cutter head is hinged to a flaring base plate and is rotatable around an axis. The flaring cutter head has multiple arc-shaped grooves that intersect the radial direction. A connecting shaft arranged axially is provided in the arc-shaped groove. One end of the connecting shaft is slidably connected in the arc-shaped groove, and the other end is connected to the end of the flaring cutter away from the stator.

[0010] According to the flexible flat wire stator flaring device provided in this application, the flaring cutter holder is provided with a drive gear that can rotate around a vertical axis by being driven by a motor; the drive gear is meshed and connected to a rack on the outer side of the flaring cutter disc.

[0011] According to the flexible flat wire stator flaring device provided in this application, the flaring chassis is provided with a plurality of guide blocks arranged at intervals along the axial direction, and a guide groove is formed between adjacent guide blocks to restrict the non-radial displacement of the flaring cutter.

[0012] According to the flexible flat wire stator flaring device provided in this application, the conveying structure includes, The transport frame is a support structure fixed on a base. The transport frame is provided with a longitudinal track arranged in the longitudinal direction and a vertical track that can be moved longitudinally and connected to the longitudinal track. An inner support gripper is vertically movable and connected to a vertical track. The inner support gripper is equipped with multiple grippers. The grippers are horizontally movable and connected to the inner support gripper via an inner support cylinder.

[0013] This application also relates to a method for flaring a flexible flat wire stator, wherein the flaring method is operated using the aforementioned flexible flat wire stator flaring device, including: The flared stator is placed on the storage structure; The handling structure picks up the stator to be flared from the storage structure and transfers it to the flaring station; The fixed structure secures the stator to be flared and the flat wire; Adjust the position of the flaring structure so that the lower end of the flat wire to be flared is inserted into the flaring structure. The flaring structure stretches the flat wire in the radial direction to complete the flaring of the flat wire. Adjust the position of the flaring structure so that the next set of flat wires to be flared can be inserted into the flaring structure, and then perform the flaring operation on that set of flat wires. This process is repeated until all the designed flared flat wires have completed the flaring operation. Then, the connection between the flaring structure, the fixing structure, and the completed flared stator is released, and the transport structure transfers the completed flared stator to the storage structure.

[0014] According to the flexible flat wire stator flaring method provided in this application, the method of adjusting the position of the flaring structure so that the lower end of the flat wire to be flared is inserted into the flaring structure includes: driving the flaring base in the flaring structure to rotate around the vertical axis, so that the flaring blade on the flaring base is aligned with the flat wire to be flared in the radial direction; driving the flaring blade disc on the flaring base to rotate, and driving the flaring blade disc to move the flaring blade radially, so that the slot on the flaring blade is aligned with the flat wire to be flared in the vertical direction; driving the flaring blade holder of the flaring structure to rise vertically, so that the slot moves up until the flat wire to be flared is inserted into the slot.

[0015] The advantages of this application are: 1. The flexible flat wire stator flaring device of this application can fix the flat wire from the root of the flat wire, which can effectively solve the problem of wire unwinding. This application fixes the flat wire in the radial direction, and the flat wire is firmly and stably fixed. It will not produce axial displacement during the flaring process. The flat wire flaring accuracy is extremely high. Moreover, the flaring device of this application performs the flaring operation from the end of the flat wire, which can adapt to stator assemblies with different inner and outer diameters, different number of slots and different number of layers. It has a high degree of flexibility and strong versatility, which solves the problem of convenient and reliable changeover for multi-variety compatible production on the production line, and ensures stable production process and product quality. 2. The fixing structure of this application includes a stator fixing structure and a flat wire fixing structure, which can stably fix the stator assembly from the inside. The flat wire fixing structure can clamp and fix the flat wire between the clamping block and the fixing post from the outside to the inside. By fixing the root of the flat wire, the flat wire is fixed stably. Moreover, the flat wire fixing operation is simple and can effectively solve the problem of wire unloading. The fixing efficiency of the flat wire and the stator assembly is high. 3. The drive structure of this application is very simple. By constructing a drive ring and the inclined groove on the drive ring, the rotational motion of the drive ring can be converted into the radial motion of the clamping block. All clamping blocks can be driven to move synchronously, so as to realize the operation of all clamping blocks clamping or releasing the flat wire synchronously. The overall operation is very simple, and clamping and releasing are very convenient. 4. The flaring structure of this application, by setting multiple radially movable flaring blades, can adapt to the flaring operation of flat wires with different inner and outer diameters on the one hand, and can adapt to the flaring operation of flat wires with different numbers of grooves and different numbers of layers by rotating the flaring base. The operation is very simple and highly versatile, making it suitable for widespread application. 5. The adjustment structure of this application adopts a flaring cutter head. The flaring cutter head has a simple structure. Through rotational motion, the flaring cutter is driven to move radially in a synchronous manner. This operation enables the flaring cutter to adapt to the flaring of flat wires with different layers and to perform flat wire flaring operations. Simultaneous operation of multiple sets can greatly improve the flaring efficiency. 6. The structure and method of driving the flaring cutter head to rotate in this application are very simple. It can synchronously drive all flaring cutters to move radially. It is easy to operate and control. The meshing structure between the flaring cutter head and the drive gear is simple to transmit and has extremely high transmission efficiency. 7. By setting a guide block, this application can effectively limit the non-radial movement of the flaring knife, making the position adjustment of the flaring knife and the flaring operation more precise. It can easily adapt to the flaring operation of flat wires with different inner and outer diameters, and the flaring effect of flat wires is excellent. 8. This application provides a handling structure that can move longitudinally and vertically. The designed internal support gripper can grasp the stator assembly from the inside of the stator assembly. The stator assembly is easy to transfer and the transfer process is stable, enabling precise grasping operation of the stator assembly. 9. This application also relates to a flexible flat wire stator flaring method. The flaring method of this application has extremely high efficiency in flaring flat wires, can adapt to the flat wire flaring operation of stator assemblies with different inner and outer diameters, and has a good flat wire flaring effect, making it suitable for widespread application. 10. This application is extremely efficient for flat wire flaring operations. It can drive the flaring knife to move synchronously, ensuring the consistency of flaring for each layer of flat wire. At the same time, it can be linked axially and radially, eliminating signal waiting, increasing the station cycle time, and greatly improving flaring efficiency.

[0016] The flexible flat wire stator flaring device of this application has a simple structure and can realize the flaring operation of stator assemblies of various specifications and models. The flat wire flaring effect is excellent, which greatly improves the processing quality of stator assemblies and has great promotional value. Attached Figure Description

[0017] Figure 1 Axial view of the flexible flat wire stator flaring device of this application; Figure 2 : Front view of the flexible flat wire stator flaring device of this application; Figure 3 : A schematic diagram of the handling structure of this application; Figure 4 : A schematic diagram of the clamping structure of this application; Figure 5 : A fixed structural axis view of this application; Figure 6 : A schematic diagram of the clamping block arrangement structure of this application; Figure 7 : A schematic diagram of the arrangement structure of the clamping block and the drive ring in this application; Figure 8 : Axial view of the flared structure of this application; Figure 9 Top view of the flared structure of this application; Figure 10 : A schematic diagram of the flaring tool structure of this application; Wherein: 1—base; 2—storage structure; 3—transportation structure; 31—Transfer frame; 32—Longitudinal rail; 33—Vertical rail; 34—Gripper; 35—Internal support cylinder; 4—Fixed structure; 41—Bracket; 42—Fixed column; 43—Base plate; 44—Clamping block; 45—Drive ring; 46—Telescopic cylinder; 47—Drive groove; 48—Slide rail; 5—flaring structure; 51—flaring tool holder; 52—flaring base; 53—flaring tool; 54—slot; 55—flaring tool disc; 56—arc-shaped groove; 57—drive gear; 58—guide block. Detailed Implementation

[0018] The embodiments of this application are described in detail below, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0019] In the description of this application, it should be understood that the terms "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0020] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0021] The present application will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0022] This application relates to a flexible flat wire stator flaring device for flaring flat wires in stator assemblies. The flaring device can adapt to the flaring of flat wires in stator assemblies of different specifications, as well as the flaring of flat wires of different quantities, layers, and slots. Before flaring the flat wires, the flaring device fixes the root of the flat wires extending from the stator assembly radially through a fixing structure, which can keep the flat wires and stator assemblies in a completely stable state during flaring, avoiding the problem of wire retraction and preventing interference with the flaring operation, thus greatly improving the efficiency and processing effect of flaring.

[0023] Specifically, such as Figures 1-10As shown, a flexible flat wire stator flaring device includes a base 1, which serves as the supporting foundation for the entire flaring device. The base 1 is equipped with a storage structure 2, a transport structure 3, a fixing structure 4, and a flaring structure 5. The storage structure 2 stores stators to be flared and stators that have already been flared. A buffer structure and a buffer station are provided on the storage structure 2, which connects to the production line for processing the entire stator assembly. The buffer station stores stator assemblies to be flared and stator assemblies that have already been flared. The transport structure 3 transfers stators to be flared from the storage structure 2 to the flaring station or transfers stators that have already been flared from the flaring station to the storage structure 2. The transport structure 3 in this application is a stator assembly gripping and transporting structure. The transport structure 3 extends into the inner ring of the stator assembly and grips the stator assembly through internal support. Simultaneously, the transport structure 3 remains fixed to the stator assembly during the flaring operation, effectively improving the efficiency of the stator assembly. Stability during the flaring operation; the fixing structure 4 is set at the flaring station to fix the root of the flat wire extending from the stator radially. The fixing structure 4 fixes the root of the flat wire radially, which makes the operation easier and the root position of the flat wire more stable, avoiding axial and radial movement of the flat wire during the flaring process and preventing interference with the flaring; the flaring structure 5 is located below the fixing structure 4. When the flat wire passes through the fixing structure 4, it is sleeved on the lower end of the flat wire and drives the lower end of the flat wire to move radially to realize the flat wire flaring operation. When flaring the flat wire, the axis of the stator assembly is arranged vertically. The flat wire at the lower end of the stator assembly passes through the fixing structure and is inserted into the flaring structure 5. The flaring structure 5 adjusts the radial position to adapt to the flat wire with different layers and adjusts the axial position to adapt to the flat wire with different slots. Then, the inserted flat wire is stretched radially, so that the lower end of the flat wire is bent radially to the set amplitude, thus completing the flaring operation of this part of the flat wire.

[0024] In practical applications, the following steps can be followed: S1. The stator to be flared is stored on storage structure 2; Storage structure 2 is equipped with a buffer station, which is connected to the stator assembly production line. After the stator completes the flat wire insertion, it can be transferred to the buffer station of storage structure 2. S2. The handling structure 3 picks up the stator to be flared from the storage structure 2 and transfers it to the flaring station. The transport structure 3 transfers the stator assembly from the cache station to the flaring station by internal support gripping. The transport structure 3 remains fixed to the stator assembly from the time it grips the stator assembly at the cache station until the stator assembly completes the flaring operation and is transferred from the flaring station to the cache station. The transport structure 3 assists the fixing structure 4 in fixing the stator assembly to ensure that the stator assembly remains stable and stationary throughout the flaring operation. S3, Fixing Structure 4: Fixing the flared stator and flat wire; The fixing structure 4 fixes the stator assembly, including fixing the stator and fixing the flat wire. Fixing the stator involves extending into the stator from bottom to top along the axial direction to limit the stator in a non-axial direction. Fixing the flat wire involves clamping and fixing the flat wire from the outside to the inside along the radial direction to limit the flat wire. S4. Adjust the position of the flaring structure 5 so that the lower end of the flat wire to be flared is inserted into the flaring structure 5. The flaring structure 5 stretches the flat wire in the radial direction to complete the flaring of the flat wire. After the stator assembly is placed on the flaring station, the fixing structure 4 completes the fixing of the stator assembly. The flat wire at the lower end of the stator assembly passes through the fixing structure 4. At this time, by adjusting the radial and circumferential positions of the flaring structure 5, the flaring structure 5 is aligned with the flat wire to be flared. The flat wire is inserted into the flaring structure 5, and the flaring structure 5 stretches the flat wire inserted into the flaring structure 5 radially, so that it bends radially to achieve the required flaring. S5. Adjust the position of the flaring structure 5 so that the next set of flat wires to be flared is inserted into the flaring structure 5 and the flaring operation of this set of flat wires is performed. After completing the flaring adjustment of a set of flat wires, the flaring structure 5 and the flared flat wires are removed. Then, the above process is followed to perform the flaring operation of the next set of flat wires. S6. Proceed sequentially until all designed flared flat lines have completed the flaring operation. Disconnect the flaring structure 5 and the fixing structure 4 from the completed flared stator. The transport structure 3 will then transfer the completed flared stator to the storage structure 2. After completing the flaring operation of all flat wires that need to be flared on the stator assembly, the handling structure 3 can transfer the stator assembly to the storage station for the next step of the operation.

[0025] In some embodiments of this application, the above-described transport structure 3 has been optimized, specifically, as follows: Figures 1-4 As shown, the handling structure 3 in this embodiment includes a handling frame 31 and an inner support gripper. The handling frame 31 is a support structure fixed on the base 1. The handling frame 31 is suspended on the entire base 1 and connects the storage station and the flaring station. The handling frame 31 is provided with a longitudinal rail 32 arranged in the longitudinal direction and a vertical rail 33 that can be moved longitudinally connected to the longitudinal rail 32. The vertical rail 33 can be moved on the longitudinal rail 32 by a motor, cylinder or other driving device. The storage station and the flaring station are arranged longitudinally at intervals. Therefore, the longitudinal rail 32 can conveniently transfer the stator assembly between the storage station and the flaring station.

[0026] Internal support clamping structure, such as Figure 4As shown, the inner support gripper includes a gripping seat, which can move up and down on the vertical track 33 via a motor, cylinder, or other driving device. That is, in this embodiment, the gripping seat can achieve longitudinal and vertical movement via the longitudinal track 32 and the vertical track 33. Multiple grippers 34 are mounted on the gripping seat, such as... Figure 4 As shown, in this embodiment, three grippers 34 are installed on the clamping base. The three grippers 34 are evenly distributed circumferentially on the clamping base with the vertical center line as the center. The grippers 34 are telescopic structures connected to the clamping base that can move horizontally. The grippers 34 are driven to move horizontally by an inner support cylinder 35. The inner support cylinder 35 drives the grippers 34 to move horizontally, which can change the radial dimension of the clamping structure formed by the grippers 34.

[0027] When the inner support cylinder 35 drives the grippers 34 to move along their respective axes toward the surrounding centerline, the radial dimension of the clamping structure formed by the grippers 34 decreases. When the radial dimension of the clamping structure formed by the grippers 34 decreases to less than the inner diameter of the stator assembly, the clamping seat is driven to move vertically downward along the vertical track 33 until the clamping seat and grippers 34 are inserted into the inside of the stator assembly. The inner support cylinder 35 then drives the grippers 34 to move away from the surrounding centerline along their respective axes, and the radial dimension of the clamping structure formed by the grippers 34 increases until one end of the grippers 34 away from the centerline is pressed against the inside of the stator assembly. After the three sets of grippers 34 are pressed against the inside of the stator assembly, the stator assembly can be fixed to the clamping structure formed by the grippers 34 by the inner support. The drive clamping seat and the clamped stator assembly move upward along the vertical track 33, disengaging from the storage station. The drive vertical track 33, clamping seat, and the clamped stator assembly move along the longitudinal track 32 to above the flaring station. The drive clamping seat and the clamped stator assembly move downward along the vertical track 33, placing the stator assembly on the flaring station. After the flaring operation is completed, the drive clamping seat and the clamped stator assembly move upward along the vertical track 33, disengaging from the flaring station. The drive vertical track 33, clamping seat, and the clamped stator assembly move along the longitudinal track 32 to above the storage station. The drive clamping seat and the clamped stator assembly move downward along the vertical track 33, placing the flared stator assembly on the storage station.

[0028] In other embodiments of this application, the storage structure 2 described above has been optimized, specifically, as follows: Figures 1-2 As shown, the storage structure 2 in this embodiment includes a storage base installed on the base 1. The upper surface of the storage base is a storage station. The base 1 is provided with a lifting drive structure. The storage base can be moved vertically by the lifting drive structure. The vertical movement of the storage base is to adapt to the stator assembly production line. In actual application, the storage base can also be designed as a fixed platform.

[0029] In a further embodiment of this application, the above-described fixing structure 4 has been optimized, specifically, as follows: Figures 5-7 As shown, the fixing structure 4 in this embodiment includes a bracket 41 fixed on the base 1. The bracket 41 is suspended on the base 1, or the bracket 41 is suspended above the flared structure 5, so that the fixing structure 4 and the flared structure 5 form an overlapping positional relationship.

[0030] The fixing structure 4 includes two levels of fixing, namely, the stator fixing structure and the flat wire fixing structure, such as... Figure 5 , 6 As shown in Figure 8, the stator fixing structure includes a vertically lifting fixing column 42. The fixing column 42 is a vertically lifting structure installed on the base 1. When the stator assembly is transported to the flaring station by the transport structure 3, the fixing column 42 rises from bottom to top and is inserted into the inner side of the stator assembly. The outer circumferential surface of the fixing column 42 is close to the inner circumferential surface of the stator assembly. The outer diameter of the fixing column 42 is equivalent to the inner diameter of the stator assembly. In actual application, a replaceable protective cover is fitted on the fixing column 42. There are various sizes of protective covers. The protective cover has a gradient structure that is smaller at the top and larger at the bottom. When in use, the protective cover that matches the stator assembly is replaced on the fixing column 42. After the protective cover and the fixing column 42 are inserted into the inner side of the stator assembly, the stator assembly can be non-axially limited. The fixing post 42 is inserted into the stator assembly from bottom to top to limit the stator assembly, and the gripper 34 of the conveying structure 3 is inserted into the stator assembly from top to bottom to limit the stator assembly. At this time, the stator assembly is completely fixed on the flaring station by the fixing post 42 and the conveying structure 3.

[0031] The flat wire fixing structure includes a base plate 43 mounted on a bracket 41. The base plate 43 has a through hole for the fixing post 42 to pass through. Multiple clamping blocks 44 are arranged radially around the through hole on the base plate 43. One end of each clamping block 44 is connected to the base plate 43 via a drive structure, allowing for telescopic movement. The other end, when the stator is placed on the base plate 43 at the flaring position, abuts against the outermost flat wire of the stator, clamping and fixing multiple flat wires in the same slot between the clamping block 44 and the fixing post 42. Each clamping block 44 has a notch on both sides near the fixing post 42. The notches of adjacent clamping blocks 44 correspond to each other, forming a U-shaped groove opening towards the fixing post 42. The width (circumferential width) of the U-shaped groove corresponds to the width of the flat wire, and the depth (radial depth) of the U-shaped groove is less than the thickness of all flat wires stacked together in one stator slot of the stator assembly. When fixing the flat wire, the adjacent clamping blocks 44 move radially toward the fixing post 42. The opening of the U-shaped groove is fitted onto the radial outer side of the stacked flat wire in one of the stator slots of the stator assembly (i.e., the outermost flat wire in the stator slot). The clamping blocks 44 squeeze the stacked flat wire and move radially toward the fixing post 42 until the radial inner side of the stacked flat wire (i.e., the innermost flat wire in the stator slot) is pressed against the outer circumference of the fixing post 42. All the flat wires in the stator slot can then be stably clamped and fixed between the clamping blocks 44 and the fixing post 42, thus completing the radial clamping and fixing of the flat wire.

[0032] The height of the U-shaped groove formed by the clamping block 44 is flush with the root of the flat wire at the lower end of the stator assembly. This means that the clamping block 44 can perform radial clamping and fixing operations on the flat wire at the root of the flat wire. On the one hand, this avoids the flat wire from shaking during the subsequent flaring process. On the other hand, the clamping block 44 will not interfere with the flaring structure (the clamping block 44 fixes the root of the flat wire, while the flaring structure connects to the end of the flat wire).

[0033] In addition, this application provides a longitudinally arranged slide rail 48 on the bracket 41, such as... Figure 5 As shown, the base plate 43 is slidably connected to the slide rail 48 along the longitudinal direction. By adjusting the position of the base plate 43 on the slide rail 48, it can adapt to the flaring requirements of stator assemblies of different specifications. For example, for a stator assembly of a certain specification, a base plate 43 corresponding to that specification is installed on the bracket 41, and the position of the base plate 43 in the longitudinal direction is adjusted so that the clamping block 44 on the base plate 43 corresponds to the fixing column 42 below and the flaring structure 5.

[0034] Furthermore, the driving structure of this embodiment is as follows: Figures 5-7As shown, the drive structure includes a drive ring 45 rotatable around an axis and connected to a base plate 43, and a telescopic cylinder 46 for driving the drive ring 45 to rotate around an axis. The drive ring 45 has drive grooves 47 that correspond one-to-one with the clamping blocks 44. The drive grooves 47 are oblique grooves that intersect the radial direction but do not coincide. A pin is provided in the drive groove 47, with one end slidably connected to the drive groove 47 and the other end of the pin connected to the end of the clamping block 44 away from the fixed post 42.

[0035] The drive groove 47 corresponds one-to-one with the clamping block 44. The drive groove 47 is an involute elongated groove structure, and there is an angle between the length direction and the radial direction of the drive groove 47, which is not 0° or 90°. The drive ring 45 is restricted on the floor 43, that is, the drive ring 45 can only rotate around its axis, and its movement in other directions is restricted. The telescopic cylinder 46 drives the drive ring 45 to rotate around the vertical axis. The rotational motion of the drive ring 45 is fed back to the pin, and the pin slides in the drive groove 47. The groove walls on both sides of the drive groove 47 push and pull the pin, which in turn acts on the clamping block 44, thus driving the clamping block 44 to move in the direction of travel. Depending on the direction of the drive groove 47, the clamping block 44 can be moved radially outward or radially inward by the rotation direction of the drive ring 45. In practical applications, a guide structure can be set on the base plate 43 to guide the radial movement of the clamping block 44 and restrict the non-radial relative movement of the clamping block 44. Of course, a guide structure can be omitted, because the circumferential sides of the clamping block 44 abut against the adjacent clamping blocks 44 on both sides, which inherently restricts the non-radial displacement between them. Figure 6 As shown, in this embodiment, a clamping ring is installed on the upper end face of the clamping block 44, and the clamping ring presses against the upper end face of the clamping block 44 to restrict the axial movement of the clamping block 44.

[0036] In actual use, the conveying structure 3 grabs the stator assembly to be flared and places it above the base plate 43, so that the stator assembly, the through hole of the base plate 43, and the fixing post 42 are arranged coaxially. The conveying structure 3 lowers the stator assembly onto the base plate 43 until the root of the flat wire at the lower end of the stator assembly is flush with the clamping block 44 in the vertical direction. The fixing post 42 is inserted vertically into the stator assembly to limit and fix the stator assembly in a non-axial direction. The telescopic cylinder 46 drives the drive ring 45 to rotate, and the drive ring 45 drives all the clamping blocks 44 to move radially toward the fixing post 42. The U-shaped groove at the end of the clamping block 44 presses and fixes the flat wire in the stator groove between the clamping block 44 and the fixing post 42, thus completing the fixation of the flat wire. After the flat wire completes the flaring operation, the telescopic cylinder 46 drives the drive ring 45 to rotate. The drive ring 45 drives all the clamping blocks 44 to move radially away from the fixed post 42. The clamping blocks 44 release the flat wire, and the fixed post 42 moves down and gets out of the stator assembly, making it convenient for the transport structure 3 to move the stator assembly away.

[0037] In a preferred embodiment of this application, the flared structure 5 described above has been optimized, specifically, as follows: Figures 8-10 As shown, the flaring structure 5 includes a flaring tool holder 51, a flaring base 52, and multiple flaring tools 53. The flaring tool holder 51 is vertically movable and mounted on the base 1. The vertical movement of the flaring tool holder 51 is to accommodate the flaring tools 53 and the flat wire. When the flat wire coincides with the flaring tool 53 in the vertical direction, the vertical movement of the flaring tool holder 51 can connect the flaring tool 53 to the lower end of the flat wire. After the flaring operation of the flat wire is completed, the downward movement of the flaring tool holder 51 facilitates the disengagement of the flaring tool 53 from the flat wire. The flaring base 52 is rotatably connected to the flaring tool holder 51 around its vertical axis. The flaring base 52 is driven by a servo motor on the flaring tool holder 51 to achieve rotational movement. The rotation of the flaring base 52 can align the flaring tools 53 on the flaring base 52 with the flat wire in the circumferential direction. For example, if a 48-slot stator assembly needs to be flared with flat wire, the flaring base 52... The 2 has eight flaring blades 53, which can perform flaring operations on eight stator slots of flat wire at a time. After completing one flaring operation, the flaring base 52 needs to be rotated to align the flaring blades 53 with the next group of flat wires in the circumferential direction, so as to facilitate the flaring operation of the next group of flat wires. The multiple flaring blades 53 are evenly spaced along the circumference. One end of the flaring blade 53 is connected to the flaring base 52 radially through an adjustment structure, and the other end has multiple slots 54 for engaging the ends of the flat wires. The radial movement of the flaring blades 53 is used to adjust the radial position of the flaring blades 53, so that the flaring blades 53 are aligned with the flat wires to be flared in the radial direction. More specifically, the slots 54 on the flaring blades 53 are aligned with the flat wires to be flared in the radial direction. On the other hand, the radial movement of the flaring blades 53 is used to drive the radial movement of the lower end of the flat wires to realize the flaring operation of the flat wires.

[0038] The adjustment structure in this embodiment is as follows: Figures 8-10 As shown, the device includes a flaring cutter head 55, which is hinged to a flaring base 52 and rotatable around its axis. The flaring cutter head 55 has multiple arc-shaped grooves 56 intersecting the radial direction. These arc-shaped grooves 56 are also involute-shaped elongated slots. A connecting shaft arranged axially is disposed within each arc-shaped groove 56. One end of the connecting shaft is slidably connected within the arc-shaped groove 56, and the other end is connected to the end of the flaring cutter 53 furthest from the stator. Each arc-shaped groove 56 corresponds one-to-one with a flaring cutter 53. The rotational motion of the flaring cutter head 55 can be converted into the radial motion of the flaring cutter 53 through the arc-shaped grooves 56. The structure of the arc-shaped grooves 56 ensures that the radial movement of the flaring cutter 53 is continuous and gapless, guaranteeing high precision in the flat wire flaring operation.

[0039] The structure of the flaring cutter head 55 is as follows: Figure 8 , 9As shown, the flaring cutter holder 51 is equipped with a drive gear 57 that can rotate around a vertical axis via a motor. The drive gear 57 is meshed with a rack on the outer circumference of the flaring cutter disc 55. The rotation of the drive gear 57 drives the rotation of the flaring cutter disc 55, and the rotational motion of the flaring cutter disc 55 is converted into the radial motion of the flaring cutter 53.

[0040] To ensure that the flaring cutter 53 always moves radially, such as Figures 8-10 As shown, in this embodiment, a plurality of guide blocks 58 are arranged axially at intervals on the flaring chassis 52, and guide grooves are formed between adjacent guide blocks 58 to restrict the non-radial displacement of the flaring cutter 53. In order to further improve the stability and accuracy of the radial movement of the flaring cutter 53, a pressure ring is provided on the flaring cutter 53 in this embodiment. The pressure ring is an annular structure located above the flaring cutter 53. A plurality of axial protrusions are provided on the lower end face of the pressure ring. The axial protrusions correspond one-to-one with the flaring cutter 53. The axial protrusions are pressed against the flaring cutter 53, and the axial protrusions are located between adjacent guide blocks 56. The axial protrusions restrict the axial movement of the flaring cutter 53.

[0041] In actual use, after the fixing structure 4 fixes the flat wire, the flaring cutter disc 55 and flaring cutter 53 are in a low position. The flaring base 52 is driven to rotate, and the flaring cutter disc 55 and flaring cutter 53 on the flaring base 52 rotate together with the flaring base 52 until the flaring cutter 53 is aligned with the flat wire to be flared in the circumferential direction. The drive gear 57 is then driven to rotate, which in turn drives the flaring cutter disc 55 to rotate. The rotation of the flaring cutter disc 55 is converted into radial movement of the flaring cutter 53 through the arc-shaped groove 53 until the slot 54 on the flaring cutter 53 is aligned with the flat wire to be flared in the vertical direction. The flaring cutter holder 51 is then driven to move vertically until the lower end of the flat wire to be flared is inserted into the corresponding slot 54, completing the flaring of the cutter 53. The connection with the flat wire is as follows: drive the drive gear 57 to rotate, which in turn drives the flaring cutter head 55 to rotate. The rotation of the flaring cutter head 55 is converted into the radial movement of the flaring cutter 53 through the arc-shaped groove 53. The flaring cutter 53 radially stretches the flat wire that is stuck in the slot 54 until the flat wire moves radially to the required extent, thus completing the flaring operation of this group of flat wires. Drive the flaring cutter holder 51 to move vertically downward, and cooperate with the rotation of the flaring base 52 to disengage the lower end of the flared flat wire from the slot 54. Then drive the flaring base 52 to rotate, so that the flaring cutter 53 rotates to the next group of flat wires to be flared. The flaring operation of this group of flat wires is carried out in the same manner as above, and so on, until all flat wires have completed the flaring operation.

[0042] This application also relates to a flexible flat wire stator flaring method, which can be carried out as follows: The clamping seat moves based on the longitudinal rail 32 and the vertical rail 33 to the top of the stator assembly to be flared on the storage rack structure 2. The inner support cylinder 35 drives the grippers 34 to move along their respective axes toward the surrounding center line, so that the radial dimension of the clamping structure formed by the grippers 34 is reduced. The clamping seat is driven to move vertically downward along the vertical rail 33 so that the clamping seat and the grippers 34 are inserted into the inside of the stator assembly. The inner support cylinder 35 drives the grippers 34 to move away from the surrounding center line along their respective axes. The three sets of grippers 34 press against the inside of the stator assembly to fix the stator assembly on the clamping structure formed by the grippers 34. The clamping seat and the clamped stator assembly are driven to move upward along the vertical rail 33 to get out of the storage position. The vertical rail 33, the clamping seat and the clamped stator assembly are driven to move along the longitudinal rail 32 to the top of the flaring position. Adjust the position of the stator assembly so that the stator assembly, the through hole of the base plate 43, and the fixing post 42 are coaxially arranged. The transport structure 3 lowers the stator assembly onto the base plate 43 until the root of the flat wire at the lower end of the stator assembly is flush with the clamping block 44 in the vertical direction. The fixing post 42 is inserted vertically into the stator assembly to limit and fix the stator assembly in a non-axial direction. The telescopic cylinder 46 drives the drive ring 45 to rotate. The drive ring 45 drives all the clamping blocks 44 to move radially toward the fixing post 42. The U-shaped groove at the end of the clamping block 44 presses and fixes the flat wire in the stator groove between the clamping block 44 and the fixing post 42, thus completing the fixation of the flat wire. The flaring base 52 is driven to rotate until the flaring cutter 53 is aligned with the flat wire to be flared in the circumferential direction; the drive gear 57 is driven to rotate, which in turn drives the flaring cutter disc 55 to rotate until the slot 54 on the flaring cutter 53 is aligned with the flat wire to be flared in the vertical direction; the flaring cutter holder 51 is driven to move vertically upward until the lower end of the flat wire to be flared is inserted into the corresponding slot 54, completing the connection between the flaring cutter 53 and the flat wire; the drive gear 57 is driven to rotate, which in turn drives the flaring cutter disc 55 to rotate, expanding... The flaring knife 53 radially stretches the flat wire that is clamped in the slot 54 until the flat wire moves radially to the required extent, thus completing the flaring operation of this group of flat wires; the flaring knife holder 51 is driven to move vertically downward, and in conjunction with the rotation of the flaring base 52, the lower end of the flat wire that has been flared is dislodged from the slot 54. Then the flaring base 52 is driven to rotate, so that the flaring knife 53 rotates to the next group of flat wires to be flared. The flaring operation of this group of flat wires is carried out in the same manner as above, and so on, until all flat wires have been flared. After all the flat wires have completed the flaring operation, the telescopic cylinder 46 drives the drive ring 45 to rotate. The drive ring 45 drives all the clamping blocks 44 to move radially away from the fixed post 42. The clamping blocks 44 release the flat wires, and the fixed post 42 moves down and disengages from the stator assembly. The drive clamping seat and the clamped stator assembly move up along the vertical track 33 to disengage from the flaring station. The drive vertical track 33, the clamping seat, and the clamped stator assembly move along the longitudinal track 32 to the storage station. The drive clamping seat and the clamped stator assembly move down along the vertical track 33 to place the flared stator assembly on the storage station, completing the operation.

[0043] like Figure 2 As shown, the vertical direction of this application is Figure 2 In the left-right direction, the vertical direction of this application is... Figure 2 The vertical direction in the middle; the radial direction in this application Figure 7 The radial direction centered on the axis of the drive ring 45, in this application, refers to the axis... Figure 7 The circumferential direction of this application is perpendicular to the paper. Figure 7 The circumferential direction centered on the axis of the drive ring 45.

[0044] The foregoing has shown and described the basic principles, main features, and advantages of this application. Those skilled in the art should understand that this application is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this application. Various changes and modifications can be made to this application without departing from the spirit and scope thereof, and all such changes and modifications fall within the scope of this application as claimed. The scope of protection of this application is defined by the appended claims and their equivalents.

Claims

1. A flexible flat wire stator flaring device, comprising a base (1), characterized in that: The base (1) is provided with, Storage structure (2), the storage structure (2) is used to store the stator to be expanded and the stator after expansion; The transport structure (3) is used to transfer the stator to be flared on the storage structure (2) to the flaring station or to transfer the stator that has been flared on the flaring station to the storage structure (2). The fixing structure (4) is set at the flaring station to fix the root of the flat wire extending out of the stator in the radial direction; A flaring structure (5) is located below a fixed structure (4); the flaring structure (5) includes a plurality of flaring blades (53) arranged circumferentially and fitted onto the lower end of the flat wire when the flat wire passes through the fixed structure (4); the flaring blades (53) are block structures that can move circumferentially and radially.

2. The flexible flat wire stator flaring device as described in claim 1, characterized in that: The fixing structure (4) includes a bracket (41) fixed to the base (1); and include, The stator fixing structure includes a vertically movable fixing column (42); the fixing column (42) is vertically inserted from bottom to top inside the stator to restrict the non-axial movement of the stator; The flat wire fixing structure includes a base plate (43) set on a bracket (41); the base plate (43) has a through hole for the fixing column (42) to pass through, and a plurality of clamping blocks (44) are arranged around the through hole on the base plate (43); the clamping blocks (44) are arranged radially, one end of which is connected to the base plate (43) through a drive structure for telescopic movement, and the other end abuts against the outermost flat wire of the stator when the stator is placed on the base plate (43) at the flaring position, so that multiple flat wires in the same slot are clamped and fixed between the clamping block (44) and the fixing column (42).

3. The flexible flat wire stator flaring device as described in claim 2, characterized in that: The drive structure includes a drive ring (45) rotatable around an axis and connected to a base plate (43), and a telescopic cylinder (46) for driving the drive ring (45) to rotate around an axis; the drive ring (45) is provided with drive grooves (47) corresponding to the clamping blocks (44); the drive grooves (47) are oblique grooves that intersect the radial direction but do not coincide, and a pin is provided in the drive groove (47) with one end slidably connected to the drive groove (47); the other end of the pin is connected to the end of the clamping block (44) away from the fixed post (42).

4. The flexible flat wire stator flaring device as described in claim 1, characterized in that: The flared structure (5) includes, Flaring tool holder (51), which is vertically and vertically mounted on the base (1); A flaring base (52) is rotatably connected to a flaring tool holder (51) about a vertical axis. One end of the flaring knife (53) is connected to the flaring base (52) radially through an adjustment structure, and the other end is provided with multiple slots (54) for snapping the ends of flat wires.

5. The flexible flat wire stator flaring device as described in claim 4, characterized in that: The adjustment structure includes, A flaring cutter head (55) is hinged to a flaring base plate (52) and can rotate around an axis. The flaring cutter head (55) has multiple arc-shaped grooves (56) that intersect the radial direction. A connecting shaft is arranged in the arc-shaped groove (56) along the axial direction. One end of the connecting shaft is slidably connected in the arc-shaped groove (56), and the other end is connected to the end of the flaring cutter (53) away from the stator.

6. The flexible flat wire stator flaring device as described in claim 5, characterized in that: The flaring cutter holder (51) is provided with a drive gear (57) that can rotate around the vertical axis by being driven by a motor; the drive gear (57) is meshed with the rack on the outer side of the flaring cutter disc (55) for transmission.

7. The flexible flat wire stator flaring device as described in claim 4, characterized in that: The flaring chassis (52) is provided with a plurality of guide blocks (58) arranged at intervals along the axial direction, and a guide groove is formed between adjacent guide blocks (58) to restrict the non-radial displacement of the flaring cutter (53).

8. The flexible flat wire stator flaring device as described in claim 1, characterized in that: The transport structure (3) includes, The transport frame (31) is a support structure fixed on the base (1). The transport frame (31) is provided with a longitudinal rail (32) arranged in the longitudinal direction and a vertical rail (33) that can be moved longitudinally and connected to the longitudinal rail (32). An inner support gripper is vertically movable and connected to a vertical track (33). The inner support gripper is provided with multiple grippers (34). The grippers (34) are horizontally movable and connected to the inner support gripper by an inner support cylinder (35).

9. A method for flaring a flexible flat wire stator, characterized in that: The flaring method is operated using a flexible flat wire stator flaring device as described in any one of claims 1 to 8, including: The stator to be flared is placed on the storage structure (2); The handling structure (3) grabs the stator to be flared on the storage structure (2) and transfers it to the flaring station; Fixed structure (4) Fix the stator to be flared and the flat wire; Adjust the position of the flaring structure (5) so that the lower end of the flat wire to be flared is inserted into the flaring structure (5). The flaring structure (5) stretches the flat wire in the radial direction to complete the flaring of the flat wire. Adjust the position of the flaring structure (5) so that the next set of flat wires to be flared is inserted into the flaring structure (5) and the flaring operation of the flat wires is performed. Proceed in sequence until all the designed flared flat wires have completed the flaring operation. Then, disconnect the flaring structure (5), the fixing structure (4), and the completed flared stator. The transport structure (3) then transfers the completed flared stator to the storage structure (2).

10. The method for flaring a flexible flat wire stator as described in claim 9, characterized in that: The method of adjusting the position of the flaring structure (5) so that the lower end of the flat line to be flared is inserted into the flaring structure (5) includes: driving the flaring base (52) in the flaring structure (5) to rotate around the vertical axis, so that the flaring knife (53) on the flaring base (52) is aligned with the flat line to be flared in the radial direction; driving the flaring knife disc (55) on the flaring base (52) to rotate, and the flaring knife disc (55) drives the flaring knife (53) to move radially, so that the slot (54) on the flaring knife (53) is aligned with the flat line to be flared in the vertical direction; driving the flaring knife holder (51) of the flaring structure (5) to rise vertically, so that the slot (54) moves up until the flat line to be flared is inserted into the slot (54).

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