A flat wire hairpin winding machine for permanent magnet motor

Abstract

The application provides a flat wire hairpin type winding machine of a permanent magnet motor, and relates to the technical field of flat wire hairpin type motor processing. The winding machine comprises a support table, a placing rack is placed on the upper side of the two ends of the support table, clamping assemblies that make close clamping actions are arranged in the placing rack, end pressing assemblies that clamp the end portions of the flat wires are arranged on the clamping assemblies, a forming seat is arranged between the placing racks, lead-through seats are fixed on the two sides of the forming seat, three-dimensional guide grooves are arranged in the lead-through seats, sliding seats are movably arranged in the three-dimensional guide grooves, and support frames one that are fixedly connected with the placing racks are rotatably connected in the sliding seats. Through the cooperation of the clamping assemblies and the end pressing assemblies, the end portions of the flat wires are prevented from being raised in the process of being bent by the cooperation of the pressing head and the forming seat. The flat wires are contacted with the cushion layer and the flexible forming belt, and the mechanical wear of the flat wires is reduced. When the flat wires are bent forward, the wear of the surface protective layer of the flat wires caused by the bending contact is greatly reduced.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of flat wire hairpin motor processing, in particular to a flat wire hairpin winding machine for a permanent magnet motor. BACKGROUND

[0002] The flat wire permanent magnet synchronous motor is a mainstream permanent magnet synchronous motor for new energy vehicles. The flat wire winding refers to winding using flat wires, and the flat wire winding has the following characteristics and advantages compared with the traditional round wire winding: 1. The flat wire winding structure is relatively compact, the space inside the motor can be fully utilized, the number of windings is increased, the filling factor of the winding is improved, and the power density and efficiency of the motor are improved. 2. Compared with the round wire winding, the flat wire winding has a larger surface area and faster heat dissipation, and the heat dissipation capacity of the motor can be improved, the temperature rise is reduced, and the reliability and service life of the motor are improved.

[0003] In the process of processing the flat wire into a hairpin structure, the 3D bending method is usually used for bending, and in this case, the protective layer outside the flat wire usually contacts the overall bending part, thereby increasing the risk of surface wear. SUMMARY

[0004] (I) Technical problems solved

[0005] In view of the defects of the prior art, the application provides a flat wire hairpin winding machine for a permanent magnet motor, which solves the problem that the flat wire 3D bending easily causes wear of the surface protective layer of the flat wire and affects the performance of the subsequent permanent magnet motor.

[0006] (II) Technical scheme

[0007] To achieve the above purpose, the application is implemented by the following technical scheme: a flat wire hairpin winding machine for a permanent magnet motor, comprising a support table, two ends of the support table are provided with a placing rack on the upper side, the placing rack is provided with a clamping assembly that moves close to each other for clamping, an end pressure assembly for clamping the end of the flat wire is arranged on the clamping assembly, a forming seat is arranged between the placing racks, two sides of the forming seat are fixed with a rotating guide seat, a three-dimensional guide groove is arranged in the rotating guide seat, a guide seat is movably arranged in the three-dimensional guide groove, a support frame one fixedly connected with the placing rack is rotatably connected in the guide seat;

[0008] A flexible forming belt is slidably arranged on the two placing racks, two chain belts are fixed at the middle part of the flexible forming belt at the forming seat, and a winding assembly for winding the chain belts is arranged in the forming seat;

[0009] A pressure head is arranged above the forming seat, a lifting assembly for driving the pressure head is fixed on the upper side of the support table, and a pad layer is fixedly attached to the lower side of the pressure head;

[0010] The lower side of the support frame one is provided with a connecting frame, one end of the connecting frame is provided with a cylinder two for driving the connecting frame to lift, and the lower side of the cylinder two is provided with a horizontal driving assembly.

[0011] Preferably, the winding assembly comprises a winding wheel, and the other ends of the two chain belts are fixed on the outer side of the winding wheel in a unified winding direction.

[0012] Preferably, the upper side of the pressing head is fixed with a connecting plate, the connecting plate is fixed with the output part of the lifting assembly, the lower side of the connecting plate is fixed with a forming column at the front side of the pressing head, and the outer side of the forming column comprises a rubber layer.

[0013] Preferably, the lower end of the support table is fixed with a base, the horizontal driving assembly comprises a cylinder three, the output end of the cylinder three is fixed with a connecting seat, the cylinder two is fixedly installed on the inner side of the connecting seat, the upper side of the base is fixedly provided with a guide rail, the connecting seat is slidably connected with the guide rail, and the base is fixed with a vertical seat for installing the cylinder three.

[0014] Preferably, the clamping assembly comprises a fixedly connected lead screw and a motor two, the motor two is fixed on the side of the placing frame away from the forming seat, the outer side of the lead screw is threadedly connected with a sliding seat, and the sliding seat is slidably connected with the placing frame.

[0015] Preferably, the end pressing assembly comprises a support seat and a rotary pressing cylinder, the support seat is fixed with the sliding seat, and the rotary pressing cylinder is installed on the support seat.

[0016] Preferably, the lifting assembly comprises a support frame two and a cylinder one, the support frame two is fixed on the support table, the part of the support frame two extending above the forming seat is installed with the cylinder one, the output end of the cylinder one is fixed with the connecting plate, the connecting plate is fixed with guide rods on both sides of the cylinder one, and the guide rods slide through the support frame two.

[0017] Preferably, the cushion layer and the flexible forming belt are both steel belts wrapped with a silica rubber layer, a soft rubber layer is wrapped on the outer side of the silica rubber layer, the flexible forming belt is in an L shape and is provided with a deformation groove at the bending part, and the silica rubber layer of the cushion layer is embedded with graphite spherical balls with a diameter of 0.05-0.35mm downwards.

[0018] (Three) beneficial effects

[0019] The application provides a flat wire winding machine for a permanent magnet motor. The following beneficial effects are achieved:

[0020] In the present application, the cooperation of the clamping assembly and the end pressing assembly prevents the end of the flat wire from being raised during the cooperation of the pressing head and the forming seat, and the contact of the cushion layer and the flexible forming belt with the flat wire reduces the mechanical wear of the flat wire, so that the wear of the surface protective layer of the flat wire caused by the bending contact is greatly reduced when the flat wire is bent forward, and the quality of the flat wire winding is improved. BRIEF DESCRIPTION OF DRAWINGS

[0021] Figure 1 It is a structural schematic view of the present application corresponding to the structure of the motor on one side of the forming seat;

[0022] Figure 2 It is a side view of the present application;

[0023] Figure 3 It is a top view of the present application;

[0024] Figure 4 It is a structural schematic view of the present application corresponding to the structure of the cylinder on the three sides of the forming seat;

[0025] Figure 5 It is Figure 4 the enlarged view of A in the middle;

[0026] Figure 6 It is Figure 4 the enlarged view of B in the middle;

[0027] Figure 7 It is a structural schematic view of the present application corresponding to the structure of the cylinder on the three sides of the forming seat;

[0028] Figure 8 It is Figure 7 a structural schematic view of the present application from the bottom of the forming seat to the upward direction;

[0029] Figure 9 It is a split schematic view of the guide seat and the transfer guide seat in the present application;

[0030] Figure 10 It is a three-dimensional guide slot schematic view of the transfer guide seat in the present application.

[0031] 1, base; 2, support seat; 3, rotating pressing cylinder; 4, support table; 5, support frame 1; 6, connecting frame; 7, transfer guide seat; 8, cushion layer; 9, connecting plate; 10, support frame 2; 11, guide rod; 12, cylinder 1; 13, pressing head; 14, flexible forming belt; 15, forming seat; 16, motor 1; 17, placing frame; 18, motor 2; 19, forming column; 20, cylinder 2; 21, guide rail; 22, cylinder 3; 23, vertical seat; 24, sliding seat; 25, guide seat; 26, three-dimensional guide slot; 27, screw rod; 28, chain belt; 29, winding wheel. DETAILED DESCRIPTION

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] like Figures 1-10 As shown, this embodiment of the invention provides a permanent magnet motor flat wire hairpin winding machine, including a base 1, a support platform 4 fixedly connected to the upper part of the base 1, and a placement frame 17 supported on the upper sides of both ends of the support platform 4. When the placement frame 17 is in a horizontal state, it is placed on both ends of the support platform 4, that is, the placement frame 17 is horizontally supported by the two ends of the support platform 4. The longitudinal section of the placement frame 17 is L-shaped, and an arc groove is provided at the bend of the L-shape. The horizontal part of the placement frame 17 is vertically continuous. A forming seat 15 is provided between the placement frames 17. The lower end of the forming seat 15 is fixedly connected to the base 1. The upper part of the forming seat 15 is provided with a forming groove that opens upward and is C-shaped. The forming groove is used for bending and forming the middle part of the straight flat wire.

[0034] Each of the placement racks 17 is equipped with a clamping assembly that performs a mutual clamping action. The clamping assembly includes a screw 27 and a motor 18 that are fixedly connected. The motor 18 is fixed on the side of the placement rack 17 away from the forming seat 15. The outer side of the screw 27 is threadedly connected to a slide 24. The screw 27 is rotatably connected within the horizontal part of the placement rack 17. The end of the screw 27 away from the motor 18 faces the forming seat 15. The slide 24 is slidably connected to the vertical passage of the horizontal part of the placement rack 17. The slide 24 includes a clamping plate that extends vertically to the upper side of the horizontal part of the placement rack 17 to hold the end of the flat wire.

[0035] The clamping assembly is equipped with an end-pressing component for clamping the end of the flat wire. Specifically, the end-pressing component consists of a support base 2 and a rotary pressing cylinder 3. The support base 2 is fixedly connected to the slide 24. The rotary pressing cylinder 3 is installed on the support base 2. During the process of the lead screw 27 driving the slide 24 to move, the support base 2 is also moved. After the clamping plate clamps the end of the straight flat wire, the rotary pressing cylinder 3 rotates to clamp the end of the straight flat wire in conjunction with the slide 24. By keeping the end of the flat wire in a pressed state with the rotary pressing cylinder 3, and cooperating with the lead screw 27 to drive the slide 24 to move, the flat wire is pulled or pushed towards the middle.

[0036] The two sides of the forming seat 15 are fixed with the transfer seat 7, the transfer seat 7 is provided with a three-dimensional guide groove 26, the three-dimensional guide groove 26 is movably provided with a guide seat 25, the guide seat 25 is rotatably connected with the support frame one 5 fixedly connected with the placing rack 17, the three-dimensional guide groove 26 is double L-shaped, specifically, the horizontal part of the first L-shaped part is located at the upper side of the transfer seat 7, and the corresponding vertical part is parallel to the vertical side surface of the forming seat 15 connecting the transfer seat 7, the second L-shaped part is bent by 90 degrees from the horizontal part of the first L-shaped part and extends forward to penetrate, that is, the whole is a three-section structure, the guide seat 25 is a square block with a rounded corner at the corner, a rotating ball is rotatably arranged in the guide seat 25, the rotating ball extends out of the guide seat 25, one end of the rotating ball is provided with a mounting plane, and the mounting plane is fixedly connected with the support frame one 5, the guide seat 25 is provided with a clamping groove on the side away from the three-dimensional guide groove 26, that is, the clamping groove is located at the side facing the mounting plane, and a guide groove is arranged on the opposite side of the three-dimensional guide groove 26 and abuts against the side surface of the rotating ball, that is, the rotating ball of the guide seat 25 can slide along the guide groove, thereby realizing the active guidance of the guide seat 25 along the three-dimensional guide groove 26.

[0037] The two placing racks 17 are slidably provided with a flexible forming belt 14, the flexible forming belt 14 is fixedly provided with two chain belts 28 at the middle part of the forming seat 15, the forming seat 15 is provided with a layout groove, the upper ends of the chain belts 28 are located in the layout groove, and the forming seat 15 is provided with a winding assembly for winding and unwinding the chain belts 28, specifically, the winding assembly comprises a winding wheel 29, the other ends of the two chain belts 28 are fixed on the outer side of the winding wheel 29 in the same winding direction, and the outer side of the forming seat 15 is provided with a motor one 16 for driving the winding wheel 29 to rotate, after the motor one 16 in the above drives the winding wheel 29 to rotate and drives the chain belts 28 to be wound, the middle part of the flexible forming belt 14 can be driven to be in a straightened state.

[0038] The forming seat 15 is provided with a pressure head 13 above, the upper side of the support table 4 is fixedly provided with a lifting assembly for driving the pressure head 13, the lower side of the pressure head 13 is fixedly provided with a cushion layer 8, after the pressure head 13 in the above is driven to move by the lifting assembly, the winding of the chain belts 28 by the winding wheel 29 is matched, the cushion layer 8 and the flexible forming belt 14 are matched as a contact surface to cooperate to bend the middle part of the flat wire, specifically, the lifting assembly comprises a support frame two 10 and a cylinder one 12, the support frame two 10 is fixedly connected to the support table 4, the part of the support frame two 10 extending to the upper side of the forming seat 15 is provided with the cylinder one 12, the output end of the cylinder one 12 is fixedly connected with a connecting plate 9, the connecting plate 9 is fixedly provided with a guide rod 11 on the two sides of the cylinder one 12, the guide rod 11 slidably passes through the support frame two 10, after the cylinder one 12 drives the connecting plate 9 to move up and down, the pressure head 13 can be driven to move downward, the upward and downward movement of the connecting plate 9 is guided by the guide rod 11, so that the pressure head 13 can be positively pressed to the forming seat 15, preventing the pressure head 13 from being inclined and dislocated relative to the forming seat 15.

[0039] The lower side of the support frame one 5 is provided with a connecting frame 6, one end of the connecting frame 6 is provided with a cylinder two 20 for driving the lifting of the connecting frame 6, after the connecting frame 6 is lifted by the cylinder two 20, the connecting frame 6 drives the support frame one 5 to move upward, at the same time, the guide base 25 moves in the three-dimensional guide groove 26, and the flat wire is bent upward by the placement rack 17.

[0040] The upper side of the pressure head 13 is fixed with a connecting plate 9, the connecting plate 9 is fixed with the output part of the lifting assembly, the lower side of the connecting plate 9 is fixed with a forming column 19 at the front side of the pressure head 13, the outer side of the forming column 19 is provided with a rubber layer embedded with graphite balls with a diameter of 0.01-0.25mm, the front side of the forming column 19 is provided with an inclined surface, and the lower end of the inclined surface is flush with the rear side of the vertical part of the flexible forming belt 14.

[0041] The lower side of the cylinder two 20 is provided with a horizontal driving assembly, the horizontal driving assembly comprises a cylinder three 22, the output end of the cylinder three 22 is fixedly connected with a connecting seat, the cylinder two 20 is fixedly installed on the inner side of the connecting seat, the upper side of the base 1 is fixedly provided with a guide rail 21, the connecting seat is slidably connected with the guide rail 21, the base 1 is fixedly provided with a vertical seat 23 for installing the cylinder three 22, and the cylinder two 20 connected with the connecting seat can move forward after the connecting seat moves forward by the cylinder three 22, so that the connecting frame 6 connected with the cylinder two 20 can drive the support frame one 5 to move forward, at this time, the support frame one 5 can swing forward from the clamping groove due to the obstruction of the part of the three-dimensional guide groove 26 located at the upper part to the front side of the guide base 25, and the flat wire bent in the middle is wound around the forming column 19 to bend the two ends forward, so that the hairpin type winding of the flat wire at the pressure head 13 and the forming column 19 is completed.

[0042] The cushion layer 8 and the flexible forming belt 14 are both steel belts wrapped with a silicon rubber layer, and the outer side of the silicon rubber layer is wrapped with a soft rubber layer, the flexible forming belt 14 is L-shaped, and is provided with a deformation groove at the bending part, and the silicon rubber layer of the cushion layer 8 is embedded with graphite balls with a diameter of 0.05-0.35mm.

[0043] The cylinder one 12, the cylinder two 20 and the cylinder three 22 are used in cooperation with the same gas source system, the gas source system, the motor one 16 and the motor two 18 are all controlled by a matching controller, and the specific control includes independent lifting or cooperative lifting of the cylinder one 12, the cylinder two 20 and the cylinder three 22, an industrial camera is installed on the side of the vertical part of the support frame two 10 towards the forming seat 15, and the pressure head 13 and the forming seat 15 are both within the machine vision range of the industrial camera before and after being close to the industrial camera.

[0044] Working principle: initially, the motor 16 drives the winding wheel 29 to wind the chain belt 28, so that the flexible forming belt 14 is in a horizontal state above the forming seat 15, after the straight flat wire in the form of a strip is placed on the flexible forming belt 14, the motor 18 drives the screw rod 27 to make the sliding seat 24 move along the placing frame 17 to the forming seat 15, so as to clamp the two ends of the straight flat wire, the rotating compression cylinder 3 drives its output end to cooperate with the sliding seat 24 to clamp the end of the straight flat wire, then the cylinder 12 drives the connecting plate 9 to make the cushion layer 8, the pressure head 13 and the forming column 19 press down, after the industrial camera obtains that the pressure head 13 contacts the straight flat wire, the motor 16 drives the winding wheel 29 to unwind the chain belt 28, so that the middle part of the straight flat wire can be driven to move downward after the continuous pressing of the pressure head 13, realizing the middle bending, then the cylinder 20 drives the connecting frame 6 to push the supporting frame 5 to move upward, in the process, the supporting frame 5 drives the rotating ball to move in the first L-shaped part of the three-dimensional guide groove 26 corresponding to the inner guide groove, and then drives the guide seat 25 to move along the three-dimensional guide groove 26, after the movement is completed, the supporting frame 5 is realized from horizontal to vertical state, and the part of the flat wire in the placing frame 17 is also in vertical state, the cylinder 22 drives the connecting seat to make the cylinder 20 move forward, and then drives the connecting frame 6 to cooperate with the supporting frame 5 to push the placing frame 17 forward, so that the supporting frame 5 will move forward from the clamping groove, in the process, the flat wire is pasted to the forming column 19 from the vertical state, the forming column 19 hinders the movement of the guide seat 25 and the part pressed by the pressure head 13, realizes the winding of the flat wire on the forming column 19, so that the end of the flat wire will face the front side.

[0045] Although embodiments of the present application have been shown and described, it is to be understood that various modifications, substitutions, replacements and changes can be made to these embodiments without departing from the principles and spirit of the present application, the scope of the present application being defined by the appended claims and their equivalents.

Claims

1. A permanent magnet motor flat wire hairpin winding machine, comprising a support platform (4), characterized in that: Placement racks (17) are placed on the upper sides of both ends of the support platform (4). Each placement rack (17) is equipped with a clamping component that performs a clamping action. An end-pressing component for clamping the end of the flat wire is provided on the clamping component. A forming seat (15) is provided between the placement racks (17). Rotary guide seats (7) are fixed on both sides of the forming seat (15). A three-dimensional guide groove (26) is provided in the rotary guide seat (7). A guide seat (25) is movably arranged in the three-dimensional guide groove (26). A support frame (5) that is fixedly connected to the placement rack (17) is rotatably connected in the guide seat (25). Flexible forming belts (14) are slidably arranged on the two placement racks (17). Two chain belts (28) are fixed in the middle of the flexible forming belts (14) at the forming base (15). A winding assembly for winding and unwinding the chain belts (28) is provided inside the forming base (15). A pressure head (13) is provided above the molding seat (15), and a lifting assembly that drives the pressure head (13) is fixed above the support platform (4). A pad layer (8) is fixedly attached to the lower side of the pressure head (13). A connecting frame (6) is provided on the lower side of the support frame (5). A cylinder (20) for driving the connecting frame (6) to rise and fall is provided on the lower side of one end of the connecting frame (6). A horizontal drive assembly is provided on the lower side of the cylinder (20).

2. The permanent magnet motor flat wire hairpin winding machine according to claim 1, characterized in that: The winding assembly includes a winding wheel (29), and the other ends of the two chain belts (28) are fixed to the outside of the winding wheel (29) in the same winding direction. A motor (16) that drives the winding wheel (29) to rotate is installed on the outside of the forming seat (15).

3. A permanent magnet motor flat wire hairpin winding machine according to claim 2, characterized in that: A connecting plate (9) is fixed on the upper side of the pressure head (13). The connecting plate (9) is fixed to the output part of the lifting assembly. A forming column (19) is fixed on the lower side of the connecting plate (9) at the front side of the pressure head (13). The outer side of the forming column (19) includes a rubber layer.

4. A permanent magnet motor flat wire hairpin winding machine according to claim 3, characterized in that: The lower end of the support platform (4) is fixed with a base (1). The horizontal drive assembly includes a cylinder three (22). The output end of the cylinder three (22) is fixed with a connecting seat. The cylinder two (20) is fixedly installed on the inner side of the connecting seat. The upper side of the base (1) is fixedly provided with a guide rail (21). The connecting seat is slidably connected with the guide rail (21). The base (1) is fixed with a stand (23) for mounting the cylinder three (22).

5. A permanent magnet motor flat wire hairpin winding machine according to claim 4, characterized in that: The clamping assembly includes a lead screw (27) and a second motor (18) that are fixedly connected. The second motor (18) is fixed on the side of the placement frame (17) away from the forming seat (15). The lead screw (27) is threadedly connected to a slide (24), which is slidably connected to the placement frame (17).

6. A permanent magnet motor flat wire hairpin winding machine according to claim 5, characterized in that: The end-pressure assembly consists of a support base (2) and a rotary pressing cylinder (3). The support base (2) is fixed to the slide (24), and the rotary pressing cylinder (3) is mounted on the support base (2).

7. A permanent magnet motor flat wire hairpin winding machine according to claim 6, characterized in that: The lifting assembly includes a second support frame (10) and a first cylinder (12). The second support frame (10) is fixed on the support platform (4). The first cylinder (12) is installed on the part of the second support frame (10) that extends above the forming seat (15). The output end of the first cylinder (12) is fixed to the connecting plate (9). The connecting plate (9) has guide rods (11) fixed on both sides of the first cylinder (12). The guide rods (11) slide through the second support frame (10).

8. A permanent magnet motor flat wire hairpin winding machine according to claim 7, characterized in that: Both the pad (8) and the flexible molding strip (14) are steel strips wrapped with a silicone rubber layer on the outside and a soft rubber layer wrapped on the outside of the silicone rubber layer. The flexible molding strip (14) is L-shaped and has a deformation groove at the bend. The silicone rubber layer of the pad (8) has a graphite sphere with a diameter of 0.05-0.35mm embedded downwards.

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