Flat wire motor manufacturing equipment and manufacturing method thereof

Abstract

This invention discloses a flat wire motor assembly equipment and its manufacturing method, relating to the technical field of equipment for assembling flat wire motors. The flat wire motor assembly equipment includes a wire feeding mechanism for placing flat wires, a stripping mechanism for stripping the enamel from the flat wires, a pulling mechanism for pulling the flat wires, a dual-channel feeding mechanism for forward delivery of the flat wires, a 2D forming mechanism for 2D forming of the flat wires, a 3D bending forming mechanism for 3D bending of the flat wires, and a wire insertion mechanism for inserting the flat wires. By employing the wire feeding mechanism, stripping mechanism, pulling mechanism, dual-channel feeding mechanism, 2D forming mechanism, 3D bending forming mechanism, and insertion mechanism, the entire process of wire feeding, enamel stripping, pulling, feeding, 2D / 3D forming, and insertion is fully automated, improving production efficiency and product consistency, reducing manual intervention, and ensuring forming accuracy and insertion reliability.

Description

Technical Field

[0001] This invention relates to the field of equipment for assembling flat wire motors, and in particular to a flat wire motor wire-making device and its wire-making method. Background Technology

[0002] With the rapid development of new energy vehicles and other fields, flat wire motors have been increasingly widely used due to their advantages such as high power density, high efficiency, and excellent thermal performance. One of the core components of a flat wire motor is the stator winding, which is composed of flat copper wires (flat wires) pre-formed into complex shapes and inserted into the stator core slots. This process places extremely high demands on the processing precision, consistency, and production efficiency of the flat wires.

[0003] Traditional flat wire manufacturing methods typically rely on multiple independent machines to complete processes such as wire laying, paint stripping, straightening, two-dimensional preforming, and three-dimensional final bending in steps. The process requires manual transfer and positioning between each step, resulting in low production efficiency, high labor intensity, and difficulty in ensuring forming accuracy and batch consistency.

[0004] Therefore, the industry urgently needs a flat wire motor manufacturing equipment and its manufacturing method that can integrate multiple processing functions and realize continuous, automatic, and high-precision processing of flat wire from raw materials to forming, so as to break through the existing technical bottlenecks and meet the core needs of modern flat wire motor manufacturing. Summary of the Invention

[0005] In view of this, the present invention addresses the deficiencies of the existing technology, and its main objective is to provide a flat wire electromechanical wire making equipment and its wire making method. It achieves full automation of wire feeding, coating stripping, wire pulling, feeding, 2D / 3D bending and forming, and wire insertion by employing a wire feeding mechanism, a coating stripping mechanism, a wire pulling mechanism, a dual-channel feeding mechanism, a flat wire 2D forming mechanism, a flat wire 3D bending and forming mechanism, and a wire insertion mechanism. This improves production efficiency and product consistency, reduces manual intervention, and ensures forming accuracy and wire insertion reliability.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A flat wire electric winding device includes a wire feeding mechanism for placing flat wires, an enamel stripping mechanism for stripping the enamel from the flat wires, a wire pulling mechanism for pulling the flat wires, a dual-channel feeding mechanism for forward feeding of the flat wires, a flat wire 2D forming mechanism for 2D forming of the flat wires, a flat wire 3D bending forming mechanism for 3D bending forming of the flat wires, and a wire insertion mechanism for inserting the flat wires. The flat wires sequentially pass through the wire feeding mechanism, the enamel stripping mechanism, the wire pulling mechanism, the dual-channel feeding mechanism, the flat wire 2D forming mechanism, and the flat wire 3D bending forming mechanism. A bending and forming mechanism and a wire insertion mechanism are included. The flat wire 3D bending and forming mechanism includes a support frame, a mold assembly for 3D bending of the flat wire, a vertical displacement drive assembly for driving the mold assembly to move vertically, a bending drive assembly for driving the mold assembly to bend the flat wire, and a protective assembly for the protective assembly. The vertical displacement drive assembly is mounted on the support frame. The mold assembly is mounted on the output end of the vertical displacement drive assembly. The mold assembly is liftably mounted on the support frame. The output end of the protective assembly is supported on the lower side of the mold assembly.

[0008] As a preferred embodiment: the mold assembly has a moving mold and a stationary mold, the moving mold is connected to the output end of the bending drive assembly, the bending drive assembly drives the moving mold to move and dock with the stationary mold; the mold assembly consists of several groups, several moving molds in several groups of mold assemblies correspond one-to-one with several stationary molds, and several moving molds and several stationary molds are vertically installed at the output end of the vertical displacement drive assembly.

[0009] As a preferred embodiment: the vertical displacement drive assembly includes a vertical displacement drive motor, a ball screw, and a vertical slide block. The ball screw is mounted on the output end of the vertical displacement drive motor and rotates with the vertical slide block. Several sets of mold assemblies are mounted on the vertical slide block. The bending drive assembly includes a bending drive cylinder and a mounting plate. The bending drive cylinder is vertically mounted on the vertical slide block, and the mounting plate is mounted on the output end of the bending drive cylinder. The mounting plate is slidably located on the vertical slide block, and the moving mold is disposed on the mounting plate.

[0010] As a preferred embodiment: the flat wire 2D forming mechanism includes a mold device for placing and forming the flat wire, a lifting drive assembly for driving the mold device to rise and fall, a forming drive assembly for driving the mold device to form the flat wire, and an anti-fall assembly for preventing the mold device from falling. The mold device is installed at the output end of the lifting drive assembly; the output end of the forming drive assembly is detachably connected to the mold device; and the output end of the anti-fall assembly is supported on the lower side of the mold device.

[0011] As a preferred embodiment: the mold device includes an upper mold and a lower mold, the upper mold being slidably connected above the lower mold, the lower mold having a forming block, and the upper mold having a forming opening that matches the forming block, the upper mold slidably bending the flat wire between the forming block and the forming opening; the forming drive assembly includes a forming drive device and a push slider, the push slider being installed at the output end of the forming drive device, and the push slider being detachably abutting against the upper mold.

[0012] As a preferred embodiment: the wire insertion mechanism includes a wire handling assembly for handling flat wires, a transfer assembly for inserting flat wires, a transfer insertion assembly for transferring flat wires from the wire handling assembly to the transfer assembly, and a buffer assembly for placing spare flat wires. The transfer insertion assembly is located between the wire handling assembly and the transfer assembly; the buffer assembly is located beside the transfer insertion assembly; the transfer assembly has a transfer mold with several flat wire placement slots for placing flat wires, and the transfer mold is movable and corresponds to the transfer insertion assembly.

[0013] As a preferred embodiment: the transfer assembly further includes a rotary drive device and a transfer drive device, the transfer drive device being installed at the output end of the rotary drive device, and the transfer mold being installed at the output end of the transfer drive device; the transfer assembly further includes a mounting plate and a lifting drive cylinder, the lifting drive cylinder being vertically mounted on the mounting plate, the transfer mold being installed at the output end of the lifting drive cylinder, and the transfer mold being liftable and detachable on the mounting plate.

[0014] As a preferred embodiment: the wire feeding mechanism includes a wire feeding reel and several straightening rollers, which are arranged in two rows, forming a straightening channel between the two rows of straightening rollers for the flat wire to pass through. The flat wire is fed from the wire feeding reel and straightened by passing through the straightening channel.

[0015] As a preferred embodiment: the paint stripping device is a paint stripping laser, there are four paint stripping lasers, and the four paint stripping lasers are respectively facing the four sides of the square flat wire; a smoke extraction pipe for smoke extraction is provided in the wire threading channel, and the smoke extraction pipe is connected to a smoke extraction machine.

[0016] As a preferred embodiment: the wire pulling mechanism includes a wire pulling assembly and a wire cutting assembly for cutting flat wires, the output end of which is movably corresponding to the wire cutting assembly; the wire pulling assembly includes a support base, a wire pulling drive motor, a toothed wheel, a toothed strip, a sliding base, and a clamping cylinder for clamping wires, the toothed strip is laterally fastened to the support base, the toothed wheel is mounted on the output end of the wire pulling drive motor and meshes with the toothed strip, the wire pulling drive motor is fastened to the sliding base, and the clamping cylinder is mounted on the sliding base.

[0017] As a preferred embodiment: the dual-channel feeding mechanism includes a feeding assembly for dual-channel conveying of flat wire, a first pushing assembly for pushing the flat wire on the feeding assembly along one of the channel directions, a second pushing assembly for pushing the flat wire on the feeding assembly along the other channel direction, a first picking assembly for clamping the flat wire pushed by the first pushing assembly, and a second picking assembly for clamping the flat wire pushed by the second pushing assembly. The feeding assembly has a first feeding plate and a second feeding plate. The first feeding plate is movably located below the first pushing assembly, and the second feeding plate is movably located below the second pushing assembly. The first picking assembly is located beside the first pushing assembly, and the second picking assembly is located beside the second pushing assembly.

[0018] The wire-making method of the flat wire electric wire-making equipment includes the following steps:

[0019] First, the flat wire is located on the wire feeding mechanism and is pulled forward by the wire pulling mechanism to achieve wire feeding;

[0020] Second, the paint stripping mechanism strips the paint from the areas of the flat wire that need to be stripped.

[0021] Third, the wire pulling component of the wire pulling mechanism pulls the flat wire forward. When the flat wire is pulled to a certain distance, the cutting component cuts the flat wire to obtain a flat wire in the form of segments of a certain distance.

[0022] Fourth, the dual-channel feeding mechanism receives the cut flat wire and uses a dual-channel feeding method for the flat wire;

[0023] Fifth, the dual-channel feeding mechanism feeds the flat wire to the flat wire 2D forming mechanism, which performs 2D forming on the flat wire;

[0024] Sixth, the flat wire is fed to the flat wire 3D bending and forming mechanism, which performs 3D bending and forming on the flat wire;

[0025] Seventh, the insertion mechanism inserts the formed flat wire into the transfer component.

[0026] Compared with existing technologies, this invention has significant advantages and beneficial effects. Specifically, as can be seen from the above technical solution, by employing a wire feeding mechanism, a paint stripping mechanism, a wire pulling mechanism, a dual-channel feeding mechanism, a flat wire 2D forming mechanism, a flat wire 3D bending forming mechanism, and a wire insertion mechanism, the entire process of wire feeding, paint stripping, wire pulling, feeding, 2D / 3D forming, and wire insertion is fully automated, improving production efficiency and product consistency, reducing manual intervention, and ensuring forming accuracy and wire insertion reliability. The wire feeding mechanism ensures the quality of the flat wire, the paint stripping mechanism improves paint stripping efficiency and the quality of the working environment, the wire pulling mechanism achieves precise wire pulling and cutting operations, and the dual-channel feeding mechanism improves feeding efficiency. The use of a mold device, lifting drive assembly, forming drive assembly, and anti-falling assembly in the flat wire 2D forming mechanism achieves efficient and accurate 2D forming of the flat wire and ensures the safety of equipment operation. The coordinated work of the mold assembly, vertical displacement drive assembly, bending drive assembly, and protective assembly in the flat wire 3D bending forming mechanism achieves efficient and accurate 3D forming of the flat wire. Safety assurance for bending and forming and mold assembly operation; the wire handling component, transfer component, transfer insertion component and buffer component in the wire insertion mechanism automatically realize the handling, transfer insertion and transfer insertion of flat wire, making the whole process of flat wire from handling to insertion smoother, improving insertion efficiency and reducing labor costs.

[0027] To more clearly illustrate the structural features and effects of the present invention, a detailed description is provided below in conjunction with the accompanying drawings and specific embodiments. Attached Figure Description

[0028] Figure 1 This is a three-dimensional structural diagram of the flat wire electric milling equipment of the present invention;

[0029] Figure 2 This is a three-dimensional structural diagram of the wire feeding mechanism of the present invention;

[0030] Figure 3 This is a three-dimensional structural diagram of the paint stripping mechanism of the present invention;

[0031] Figure 4 This is a three-dimensional structural diagram of the wire-pulling mechanism of the present invention;

[0032] Figure 5 This is a first-view perspective three-dimensional structural diagram of the dual-channel feeding mechanism of the present invention;

[0033] Figure 6 This is a second-view three-dimensional structural diagram of the dual-channel feeding mechanism of the present invention;

[0034] Figure 7 This is a three-dimensional structural diagram of the first material handling component of the present invention;

[0035] Figure 8 This invention Figure 6Enlarged view at point M;

[0036] Figure 9 This is a first-view three-dimensional structural diagram of the flat wire 2D forming mechanism of the present invention.

[0037] Figure 10 This is a second-view three-dimensional structural diagram of the flat wire 2D forming mechanism of the present invention;

[0038] Figure 11 This is a third-view three-dimensional structural diagram of the flat wire 2D forming mechanism of the present invention.

[0039] Figure 12 This invention Figure 9 Enlarged view at point N;

[0040] Figure 13 This invention Figure 10 Enlarged view at point P;

[0041] Figure 14 This is a three-dimensional structural diagram of the mold device of the present invention;

[0042] Figure 15 This is a first-view three-dimensional structural diagram of the flat wire 3D bending and forming mechanism of the present invention.

[0043] Figure 16 This is a second-view three-dimensional structural diagram of the flat wire 3D bending and forming mechanism of the present invention.

[0044] Figure 17 This is a schematic diagram of the three-dimensional structure of the moving mold and the stationary mold of the present invention;

[0045] Figure 18 This invention Figure 15 Enlarged view of point Q;

[0046] Figure 19 This is a three-dimensional structural diagram of the insertion mechanism of the present invention;

[0047] Figure 20 This is a three-dimensional structural diagram of the wire handling assembly of the present invention;

[0048] Figure 21 This is a schematic diagram of the three-dimensional structure of the clamping component of the present invention;

[0049] Figure 22 This is a three-dimensional structural diagram of the transfer component of the present invention;

[0050] Figure 23 This is a three-dimensional structural diagram of the intermediate transfer mold and lifting drive cylinder of the present invention;

[0051] Figure 24 This is a three-dimensional structural diagram of the transfer insertion assembly of the present invention.

[0052] Explanation of reference numerals in the attached diagram:

[0053] In the diagram: 100, wire feeding mechanism; 11, wire feeding reel; 12, straightening wheel; 13, straightening channel; 200, paint stripping mechanism; 21, wire threading channel; 22, paint stripping device; 23, smoke extraction pipe; 24, wire feeding pipe; 25, wire feeding trough; 300, wire pulling mechanism; 311, support base; 312, wire pulling drive motor; 313, toothed wheel; 314, toothed rack; 315, sliding base; 316, gripper cylinder; 321, wire cutting drive cylinder; 400, dual-channel feeding mechanism; 410, feeding assembly; 411, first feeding plate; 412, second feeding plate; 413, feeding trough; 414, longitudinal feeding drive device. ; 4141, Double-acting linear motor; 4142, First sliding mounting base; 4143, Second sliding mounting base; 415, First vertical anti-interference device; 416, Second vertical anti-interference device; 4151, Vertical drive cylinder; 4152, Anti-interference slide; 41521, Passage gap; 420, First pushing assembly; 421, Pushing drive device; 422, Pushing slide plate; 430, Second pushing assembly; 440, First picking assembly; 441, Longitudinal drive device; 442, Vertical drive device; 443, Rotary drive motor; 444, Clamping cylinder; 450, Second picking assembly; 500, Flat wire 2D Molding mechanism; 510, mold device; 511, upper mold; 5111, molding opening; 5112, slotting; 512, lower mold; 5121, molding block; 5122, buffer spring; 520, lifting drive assembly; 521, lifting drive motor; 522, vertical lead screw; 523, vertical slide; 524, lifting guide rail; 530, molding drive assembly; 531, molding drive device; 532, pushing slider; 540, anti-fall assembly; 541, anti-fall drive cylinder; 542, pallet; 600, flat wire 3D Bending and forming mechanism; 610, support frame; 620, mold assembly; 621, moving mold; 6211, guide slant block; 6212, bending protrusion; 622, stationary mold; 6222, wire feeding slot; 630, vertical displacement drive assembly; 631, vertical displacement drive motor; 632, ball screw; 633, vertical slide block; 640, bending drive assembly; 641, bending drive cylinder; 642, mounting slide plate; 650, protective assembly; 651, protective drive cylinder; 652, protective plate; 700, wire insertion mechanism; 710, wire handling assembly. 7111, Base; 7112, Rotary motor; 7113, Turntable; 7114, Arc track; 712, Wire clamping device; 7121, Main body; 7122, Wire clamping component; 71221, Wire clamping claw; 71222, Drive component; 7123, Roller; 7124, Wire pressing component; 71241, Wire pressing support; 71242, Wire pressing arm; 71243, Drive arm; 71244, Gear; 71245, Rack; 713, Drive device; 7131, Push block; 7132, Moving drive cylinder; 720, Transfer assembly;721. Transfer mold; 7211. Flat wire feeding trough; 722. Rotary drive device; 723. Transfer drive device; 724. Mounting plate; 725. Lifting drive cylinder; 730. Transfer insertion assembly; 731. Robotic arm; 732. Longitudinal drive device; 733. Vertical drive device; 734. Wire clamping cylinder; 740. Buffer assembly; 741. Wire feeding block. Detailed Implementation

[0054] The present invention is as follows Figure 1 As shown in Figure 24, a flat wire electric winding device includes a wire feeding mechanism 100 for placing flat wires, a stripping mechanism 200 for stripping the enamel from the flat wires, a pulling mechanism 300 for pulling the flat wires, a dual-channel feeding mechanism 400 for forward delivery of the flat wires, a flat wire 2D forming mechanism 500 for 2D forming of the flat wires, a flat wire 3D bending forming mechanism 600 for 3D bending forming of the flat wires, and a wire insertion mechanism 700 for inserting the flat wires. The flat wires pass sequentially through the wire feeding mechanism 100, the stripping mechanism 200, the pulling mechanism 300, the dual-channel feeding mechanism 400, the flat wire 2D forming mechanism 500, the flat wire 3D bending forming mechanism 600, and the wire insertion mechanism 700.

[0055] The stripping mechanism 200 includes a threading channel 21 for the flat wire to pass through and a stripping device 22 for stripping the flat wire, the flat wire passing through the threading channel 21 and the stripping device 22 facing the flat wire; the wire pulling mechanism 300 includes a wire pulling assembly and a wire cutting assembly for cutting the flat wire, the output end of the wire pulling assembly being movably corresponding to the wire cutting assembly.

[0056] The wire feeding mechanism 100 includes a wire feeding reel 11 and several straightening rollers 12. The several straightening rollers 12 are arranged in two rows, and a straightening channel 13 is formed between the two rows of straightening rollers 12 for the flat wire to pass through. The flat wire is fed by the wire feeding reel 11 and straightened by passing through the straightening channel 13.

[0057] The wire feeding mechanism 100 employs a combination design of a wire feeding reel 11 and several straightening rollers 12, offering significant advantages. The wire feeding reel 11 can stably hold continuous flat wire, ensuring a continuous wire supply. The straightening channel 13 formed by the two rows of straightening rollers 12 effectively straightens the flat wire fed from the wire feeding reel 11. In actual production, flat wire is prone to bending and deformation when wound on the wire feeding reel 11. After passing through the straightening channel 13, the flat wire can be restored to a straight state, providing a good foundation for subsequent processes such as paint stripping and wire insertion, thus improving the processing accuracy and finished product quality of the flat wire.

[0058] The paint stripping device 22 is a paint stripping laser, and there are four paint stripping lasers, which are respectively facing the four sides of the square flat wire; a smoke extraction pipe 23 for smoke extraction is provided in the wire passage 21, and the smoke extraction pipe 23 is connected to a smoke extractor.

[0059] The paint stripping mechanism 200 also includes a wire feeding tube 24 for placing the paint stripping laser wire. The wire feeding tube 24 is arc-shaped, and a wire feeding groove 25 matching the wire feeding groove of the paint stripping laser is provided on the upper side of the wire feeding tube 24.

[0060] Paint stripping device 22: The paint stripping device 22 uses four paint stripping lasers, each pointing towards one of the four sides of the square flat wire, improving paint stripping efficiency. Traditional paint stripping methods may require multiple operations to complete the stripping of each side of the flat wire, while this device can strip the paint from all four sides simultaneously, greatly shortening the stripping time. Moreover, laser paint stripping has the advantages of high precision and minimal damage to the flat wire, better ensuring the performance of the flat wire.

[0061] Smoke extraction pipe 23 and smoke extractor: A smoke extraction pipe 23 is installed at the wiring channel 21 and connected to a smoke extractor to promptly remove fumes generated during the paint stripping process. The fumes produced during paint stripping may contain harmful substances, which not only affect the working environment but may also harm the health of operators. The installation of the smoke extraction pipe 23 and the smoke extractor effectively improves the working environment and protects the health of operators.

[0062] Cable delivery tube 24: The arc-shaped cable delivery tube 24 equipped with the paint stripping mechanism 200 has a cable delivery groove 25 on its upper side that matches the cable of the paint stripping laser. This design provides an orderly placement space for the cable of the paint stripping laser, avoids messy tangling of the cable, facilitates equipment maintenance and management, and also ensures the normal operation of the paint stripping laser.

[0063] The wire pulling assembly includes a support base 311, a wire pulling drive motor 312, a toothed wheel 313, a toothed rack 314, a sliding base 315, and a gripper cylinder 316 for clamping the wire. The toothed rack 314 is laterally fastened to the support base 311. The toothed wheel 313 is installed at the output end of the wire pulling drive motor 312 and meshes with the toothed rack 314. The wire pulling drive motor 312 is fastened to the sliding base 315, and the gripper cylinder 316 is installed on the sliding base 315.

[0064] The wire cutting assembly includes a wire cutting drive cylinder 321 and a cutter. The wire cutting drive cylinder 321 is vertically mounted on a support base 311, and the cutter is mounted on the output end of the wire cutting drive cylinder 321. The gripper cylinder 316 drives the flat wire to move to the cutter position.

[0065] Wire pulling assembly: The wire pulling assembly achieves precise wire pulling action through the meshing transmission of toothed wheel 313 and toothed rack 314. The wire pulling drive motor 312 drives the toothed wheel 313 to rotate. Because the toothed wheel 313 meshes with the toothed rack 314, the sliding seat 315 can move stably along the toothed rack 314, thereby driving the gripper cylinder 316 to clamp and move the flat wire. This transmission method has high precision and good stability, accurately controlling the pulling length of the flat wire and ensuring the consistency of the flat wire's length in subsequent processing.

[0066] Wire Cutting Assembly: The wire cutting drive cylinder 321 in the wire cutting assembly is vertically mounted on the support base 311, and the cutter is installed at its output end. When the wire pulling assembly pulls the flat wire to a predetermined length, the wire cutting drive cylinder 321 actuates, driving the cutter to cut the flat wire. This design makes the cutting action rapid and accurate, improving production efficiency, and ensuring a flat cut surface, which is beneficial for subsequent assembly processes.

[0067] The dual-channel feeding mechanism 400 includes a feeding assembly 410 for dual-channel conveying of flat wire, a first pushing assembly 420 for pushing the flat wire on the feeding assembly 410 along one of the channel directions, a second pushing assembly 430 for pushing the flat wire on the feeding assembly 410 along the other channel direction, a first picking assembly 440 for clamping the flat wire pushed by the first pushing assembly 420, and a second picking assembly 450 for clamping the flat wire pushed by the second pushing assembly 430, wherein:

[0068] The feeding assembly 410 has a first feeding plate 411 and a second feeding plate 412. The first feeding plate 411 is movably located below the first pushing assembly 420, and the second feeding plate 412 is movably located below the second pushing assembly 430. The first picking assembly 440 is located beside the first pushing assembly 420, and the second picking assembly 450 is located beside the second pushing assembly 430.

[0069] It consists of a feeding assembly 410, a first pushing assembly 420, a second pushing assembly 430, a first picking assembly 440, and a second picking assembly 450. It achieves dual-channel synchronous feeding of the flat wire, significantly improving feeding efficiency, shortening the production cycle, and reducing production costs compared to the traditional single-channel feeding method. Simultaneously, the clear division of labor and mutual cooperation among the components make the feeding process more orderly and efficient, improving the overall operational stability of the equipment.

[0070] Both the first feeding plate 411 and the second feeding plate 412 have several feeding slots 413 for placing flat wires. The feeding slots 413 are matched with the shape and size of the flat wires. The feeding slots 413 provide a precise placement position for the flat wires, ensuring the stability of the flat wires during the feeding process and avoiding shaking or deviation of the flat wires during the conveying process. This improves the accuracy and reliability of the feeding and provides a good foundation for subsequent wire manufacturing processes.

[0071] The feeding assembly 410 consists of two sets, which are distributed in parallel. The feeding assembly 410 also includes a longitudinal feeding drive device 414, a first vertical anti-interference device 415, and a second vertical anti-interference device 416. The first vertical anti-interference device 415 and the second vertical anti-interference device 416 are both installed at the output end of the longitudinal feeding drive device 414. The first feeding plate 411 is installed at the output end of the first vertical anti-interference device 415. The second feeding plate 412 is installed at the output end of the second vertical anti-interference device 416.

[0072] The longitudinal feeding drive device 414 includes a dual-actuator linear motor 4141, a first sliding mounting base 4142, and a second sliding mounting base 4143. Both the first sliding mounting base 4142 and the second sliding mounting base 4143 are mounted on the output end of the dual-actuator linear motor 4141. The dual-actuator linear motor 4141 has high motion accuracy and response speed, and can accurately control the longitudinal movement of the first sliding mounting base 4142 and the second sliding mounting base 4143, thereby realizing the precise positioning and feeding of the first feeding plate 411 and the second feeding plate 412, and improving the accuracy and efficiency of feeding.

[0073] The first vertical anti-interference device 415 and the second vertical anti-interference device 416 both include a vertical drive cylinder 4151 and an anti-interference slide 4152. The vertical drive cylinder 4151 of the first vertical anti-interference device 415 is mounted on the first sliding mounting base 4142, and the vertical drive cylinder 4151 of the second vertical anti-interference device 416 is mounted on the second sliding mounting base 4143. The anti-interference slide 4152 is mounted at the output end of the vertical drive cylinder 4151.

[0074] The anti-interference slide 4152 has a passageway 41521 for the passage of the first feed plate 411 or the second feed plate 412. The two sets of parallel feeding assemblies 410 prevent interference in the feeding position through the passageway 41521.

[0075] The parallel distribution of the two sets of feeding components 410 enables dual-channel feeding, further improving feeding efficiency. The anti-interference slide 4152 in the anti-interference device has a passageway gap 41521, which effectively prevents positional interference between the two sets of feeding components 410 during feeding, ensuring smooth feeding, avoiding feeding failures and equipment damage caused by interference, and improving equipment lifespan and production continuity.

[0076] The first pusher assembly 420 and the second pusher assembly 430 both include a pusher drive device 421 and a pusher slide plate 422, with the pusher slide plate 422 mounted on the output end of the pusher drive device 421.

[0077] The material pushing drive device 421 includes a material pushing drive motor and a transmission belt. The transmission belt is installed at the output end of the material pushing drive motor, and the material pushing slide plate 422 is fastened to the transmission belt.

[0078] The pusher drive motor drives the pusher slide plate 422 to move via a transmission belt, which can accurately push the flat wire on the feeding plate along the corresponding channel direction. This transmission method has the characteristics of simple structure and high transmission efficiency, and can complete the pushing action quickly and stably, ensuring the timeliness and accuracy of feeding.

[0079] The first material handling assembly 440 and the second material handling assembly 450 both include a longitudinal drive device 441, a vertical drive device 442, a rotary drive motor 443, and a clamping cylinder 444. The vertical drive device 442 is installed at the output end of the longitudinal drive device 441, the rotary drive motor 443 is installed at the output end of the vertical drive device 442, and the clamping cylinder 444 is installed at the output end of the rotary drive motor 443.

[0080] The longitudinal drive device 441 and the vertical drive device 442 enable the clamping cylinder 444 to move flexibly in the longitudinal and vertical directions, accurately reaching the position for pushing the flat wire. The rotary drive motor 443 can adjust the angle of the flat wire according to actual needs, improving the flexibility and adaptability of material handling. The clamping cylinder 444 can firmly clamp the flat wire, ensuring that it will not fall off during material handling and conveying, thus guaranteeing the integrity and reliability of feeding.

[0081] The longitudinal drive device 441 includes a longitudinal drive motor, a lead screw, and a longitudinal slide. The lead screw is mounted on the output end of the longitudinal drive motor, and the longitudinal slide is rotatably engaged with the lead screw. The vertical drive device 442 includes a vertical cylinder and a vertical slide. The vertical cylinder is mounted on the longitudinal slide, and the vertical slide is mounted on the output end of the vertical cylinder.

[0082] By setting up a dual-channel feeding assembly 410 and corresponding first pushing assembly 420, second pushing assembly 430, first picking assembly 440 and second picking assembly 450, dual-channel synchronous feeding of flat wire is achieved, improving production efficiency. During feeding, interference at the feeding position is avoided, ensuring feeding accuracy. Compared with traditional single-channel feeding mechanisms, dual-channel synchronous feeding of flat wire improves production efficiency and reduces production time and cost. The feeding trough 413 matches the shape and size of the flat wire, accurately positioning it and ensuring stability and accuracy during feeding. The two sets of feeding assemblies 410 are distributed in parallel and equipped with a first vertical anti-interference device 415 and a second vertical anti-interference device 416. The passage gap 41521 of the anti-interference slide 4152 effectively avoids interference at the feeding position, ensuring feeding accuracy and wire quality.

[0083] The flat wire 2D forming mechanism 500 includes a mold device 510 for placing and forming the flat wire, a lifting drive assembly 520 for raising and lowering the mold device 510, a forming drive assembly 530 for driving the mold device 510 to form the flat wire, and an anti-fall assembly 540 for preventing the mold device 510 from falling.

[0084] The mold device 510 is installed at the output end of the lifting drive assembly 520; the output end of the molding drive assembly 530 is detachably connected to the mold device 510; the output end of the anti-fall assembly 540 is supported on the lower side of the mold device 510.

[0085] The mold device 510 includes an upper mold 511 and a lower mold 512. The upper mold 511 is slidably connected above the lower mold 512. The lower mold 512 has a forming block 5121. The upper mold 511 has a forming opening 5111 that matches the forming block 5121. The upper mold 511 can slidably bend the flat wire between the forming block 5121 and the forming opening 5111. A buffer spring 5122 is provided between the upper mold 511 and the lower mold 512.

[0086] The molding drive assembly 530 includes a molding drive device 531 and a pusher slider 532. The pusher slider 532 is mounted on the output end of the molding drive device 531 and is detachably abutted against the upper mold 511. The molding drive device 531 includes a molding drive motor and a cam. The cam is mounted on the output end of the molding drive motor. The profile surface of the cam is configured to act on the pusher slider 532 so that the pusher slider 532 is forced to produce reciprocating linear motion as the cam rotates.

[0087] The upper mold 511 has a slot 5112 on its rear side. The front end of the push slider 532 is detachably located in the slot 5112. The slot 5112 slides and engages with the front end of the push slider 532 as the upper mold 511 can be raised and lowered.

[0088] The lifting drive assembly 520 includes a lifting drive motor 521, a vertical lead screw 522, and a vertical slide block 523. The vertical lead screw 522 is installed at the output end of the lifting drive motor 521, and the vertical lead screw 522 is rotatably engaged with the vertical slide block 523. The mold device 510 is installed on the vertical slide block 523.

[0089] The mold device 510 consists of several groups, which are installed in layers from top to bottom on the vertical slide block 523. The mold devices 510 can be raised and lowered to connect with the molding drive assembly 530.

[0090] The lifting drive assembly 520 also includes two lifting guide rails 524, which are arranged in parallel. Both vertical guide rails slide in cooperation with the vertical slide block 523.

[0091] The anti-fall assembly 540 includes an anti-fall drive cylinder 541 and a support plate 542. The support plate 542 is installed at the output end of the anti-fall drive cylinder 541 and supports the lower side of the mold device 510.

[0092] This flat wire 2D forming mechanism combines the mold device 510, the lifting drive component 520, the forming drive component 530, and the anti-fall component 540, enabling each component to work together and complete the flat wire 2D forming process in an orderly manner. This improves the integration and efficiency of the equipment, while ensuring the safety and stability of the entire forming process.

[0093] The upper mold 511 can slide between the forming block 5121 and the forming opening 5111 to bend the flat wire, which is initially straight, into a "U" shape. This structural design can precisely control the forming shape and size of the flat wire, ensuring the high precision of the 2D forming of the flat wire and meeting the strict requirements of the flat wire motor assembly for the shape of the flat wire.

[0094] The multi-die device 510 can sequentially form multiple flat wires, improving the efficiency of flat wire forming and meeting the needs of large-scale production. The multi-die device 510 can be configured with different sizes of dies according to the different sizes and models of the flat wires, making it widely applicable.

[0095] The push slider 532 is detachably connected to the upper mold 511, and the slot 5112 on the rear side of the upper mold 511 slides with the front end of the push slider 532, so that the push slider 532 corresponds to the mold device 510 at different height positions during the lifting and lowering process of the mold device 510, thereby enhancing the versatility and flexibility of the equipment.

[0096] Two parallel lifting guide rails 524 are set up to slide in cooperation with the vertical slide block 523. The guide rails play a guiding and supporting role, which can effectively prevent the vertical slide block 523 from shaking or deviating during the lifting process, further improving the lifting accuracy and stability of the mold device 510 and ensuring the quality of flat wire forming.

[0097] During the operation of the mold device 510, the anti-fall component 540 provides reliable support for the mold device 510, preventing it from falling due to accidents, ensuring the safe operation of the equipment, reducing maintenance costs and production delays caused by mold damage, and protecting the safety of operators.

[0098] High-efficiency forming: The forming drive assembly 530 adopts a combination of cam and push slider 532, which can convert the rotational motion of the forming drive motor into the reciprocating linear motion of the push slider 532, thereby achieving high-efficiency driving of the mold device 510 and improving the efficiency of flat wire forming.

[0099] Precise control: The lifting drive assembly 520 adopts a combination of lifting drive motor 521, vertical lead screw 522 and vertical slide 523, which can precisely control the lifting position of mold device 510, making it easy to operate mold device 510 at different positions. At the same time, the layered arrangement of multiple mold devices 510 can realize the forming operation of multiple flat wires at the same time, improving production efficiency. The multiple mold devices 510 are set with corresponding dimensions according to the size and model of flat wire, making them widely applicable.

[0100] Flexible docking: The slot 5112 on the rear side of the upper mold 511 and the separable sliding engagement of the front end of the push slider 532 allow multiple sets of mold devices 510 to be raised and lowered and docked with the forming drive assembly 530 respectively, which improves the flexibility and applicability of the forming mechanism. The mold devices 510 participating in the forming operation can be flexibly adjusted according to actual production needs, which effectively improves the production efficiency of flat wire forming and the overall utilization rate of the equipment.

[0101] The usage method and principle of the flat wire 2D forming mechanism 500 used in flat wire motor assembly are as follows:

[0102] Flat wire placement: Place the flat wire on the forming block 5121 of the lower mold 512; Mold device 510 lifting: Start the lifting drive motor 521, which drives the vertical lead screw 522 to rotate. The vertical lead screw 522 and the vertical slide block 523 rotate and cooperate, causing the vertical slide block 523 to rise and fall along the lifting guide rail 524, thereby driving the mold device 510 to rise and fall to the appropriate forming position. Flat wire forming: Start the forming drive motor, the cam rotates, and its contour surface acts on the push slider 532, forcing the push slider 532 to produce reciprocating linear motion. The push slider 532 pushes the upper mold 511 to slide on the forming block 5121, bending the flat wire between the forming block 5121 and the forming opening 5111, completing the 2D forming of the flat wire. Anti-fall protection: During the operation of the mold device 510, the anti-fall drive cylinder 541 drives the support plate 542 to rise and support the lower side of the mold device 510 to prevent the mold device 510 from falling.

[0103] The flat wire 3D bending forming mechanism 600 includes a support frame 610, a mold assembly 620 for 3D bending of the flat wire, a vertical displacement drive assembly 630 for driving the mold assembly 620 to move vertically, a bending drive assembly 640 for driving the mold assembly 620 to bend the flat wire, and a protective assembly 650 for the protective assembly 650, wherein:

[0104] The vertical displacement drive assembly 630 is mounted on the support frame 610; the mold assembly 620 is mounted on the output end of the vertical displacement drive assembly 630; the mold assembly 620 is liftably mounted on the support frame 610; the output end of the protective assembly 650 is supported on the lower side of the mold assembly 620; the mold assembly 620 has a moving mold 621 and a stationary mold 622, the moving mold 621 is connected to the output end of the bending drive assembly 640, and the bending drive assembly 640 drives the moving mold 621 to move and dock with the stationary mold 622.

[0105] The mold assembly 620 consists of several groups, with several moving molds 621 and several stationary molds 622 corresponding one-to-one. The moving molds 621 and the stationary molds 622 are vertically installed at the output end of the vertical displacement drive assembly 630. The moving molds 621 correspond to several different sizes and models of flat wires. The flat wires are initially planar "U" shapes, and after being bent by the mold assembly 620, they take on a 3D three-dimensional shape with a bent arc at the top.

[0106] The vertical displacement drive assembly 630 includes a vertical displacement drive motor 631, a ball screw 632, and a vertical slide block 633. The ball screw 632 is installed at the output end of the vertical displacement drive motor 631 and rotates with the vertical slide block 633. Several sets of mold assemblies 620 are installed on the vertical slide block 633.

[0107] The bending drive assembly 640 includes a bending drive cylinder 641 and a mounting plate 642. The bending drive cylinder 641 is vertically mounted on a vertical sliding block 633. The mounting plate 642 is mounted on the output end of the bending drive cylinder 641 and is slidably located on the vertical sliding block 633. The moving mold 621 is disposed on the mounting plate 642.

[0108] The vertical sliding block 633 has a vertical groove for the mounting plate 642 to slide. The moving mold 621 slides in the vertical groove along with the mounting plate 642. The moving mold 621 moves and docks with the stationary mold 622 to bend the flat wire into shape.

[0109] Both the moving mold 621 and the stationary mold 622 are provided with guide blocks 6211, and the guide blocks 6211 of the moving mold 621 and the guide blocks 6211 of the stationary mold 622 are wedge-shaped; the flat line is located between the moving mold 621 and the stationary mold 622.

[0110] The stationary mold 622 has a wire feeding slot 6222 for placing flat wire, and the moving mold 621 has a bending protrusion 6212 that matches the wire feeding slot 6222. The bending protrusion 6212 moves with the moving mold 621 to bend and shape the flat wire in the wire feeding slot 6222.

[0111] The protective assembly 650 includes a protective drive cylinder 651 and a protective plate 652. The protective drive cylinder 651 is vertically mounted on the support frame 610. The protective plate 652 is mounted on the output end of the protective drive cylinder 651 and is supported on the lower side of the mold assembly 620.

[0112] The mold assembly 620 consists of several groups, with several moving molds 621 corresponding to several different sizes and models of flat wire. This gives the mechanism strong versatility, eliminating the need for frequent equipment or mold changes during production. It enables rapid 3D bending and forming of flat wires of different sizes, reducing equipment debugging time and production costs, and improving production flexibility and adaptability. Achieving 3D forming: The flat wire initially has a planar "U" shape, which, after being bent by the mold assembly 620, takes on a 3D three-dimensional shape with a bent arc at the top. This complex 3D forming is difficult to achieve with traditional bending equipment, meeting the needs of modern industry for complex shapes of flat wires, broadening the application range of flat wires, and increasing the added value of products.

[0113] The vertical displacement drive component 630 can achieve precise control of the vertical position of the mold component 620, with high positioning accuracy, ensuring that the mold component 620 can accurately reach the predetermined working position, thereby guaranteeing the accuracy and consistency of flat wire bending and forming.

[0114] The bending drive assembly 640 can flexibly drive the moving die 621 to move and dock with the stationary die 622 to complete the bending action of the flat wire. Moreover, the mounting slide 642 slides in the vertical groove of the vertical sliding block 633, which further ensures the straightness and stability of the movement of the moving die 621 and improves the bending quality.

[0115] The guide block 6211 plays a role in precise guidance and positioning, ensuring that the moving mold 621 can be accurately aligned with the stationary mold 622, avoiding problems such as inaccurate bending or damage to the flat wire caused by positional deviation, and improving the accuracy and reliability of bending forming.

[0116] The wire feeding slot 6222 accurately positions the flat wire, providing a precise reference for the bending operation. The bending protrusion 6212 moves with the moving die 621 to bend the flat wire in the wire feeding slot 6222. This precise fit allows the flat wire to deform according to the predetermined shape and size during the bending process, ensuring bending accuracy and consistency and improving product quality.

[0117] High-efficiency and precise molding: Through the cooperation of the moving mold 621 and the stationary mold 622 of the mold assembly 620, flat wires that are initially planar "U"-shaped can be 3D bent into a 3D three-dimensional shape with a bent arc at the top, meeting complex molding requirements. The setting of multiple sets of mold assemblies 620 can process flat wires of different sizes and models simultaneously or sequentially, improving molding efficiency and equipment versatility.

[0118] Flexible drive control: The vertical displacement drive assembly 630 uses a vertical displacement drive motor 631 and a ball screw 632 to precisely control the vertical position of the mold assembly 620, ensuring that the mold assembly 620 accurately reaches the predetermined working position. The bending drive assembly 640 uses a bending drive cylinder 641 to drive the mounting slide plate 642 and the moving mold 621 to slide, realizing the bending operation of the flat wire. This drive method is simple to operate, has a fast response, and can flexibly control the bending process.

[0119] Safety protection: The protective plate 652 of the protective component 650 is attached to the lower side of the mold component 620, which effectively prevents the mold component 620 from falling during operation, ensuring the safe operation of the equipment and reducing equipment damage and production safety accidents caused by mold falling.

[0120] Accurate guidance and positioning: The wedge-shaped fit of the guide blocks 6211 on the moving mold 621 and the stationary mold 622, as well as the matching of the bending protrusion 6212 of the moving mold 621 and the wire feeding slot 6222 of the stationary mold 622, ensure the accuracy and stability of the docking of the moving mold 621 and the stationary mold 622, and improve the precision of flat wire bending and forming.

[0121] The usage method and principle of this flat wire 3D bending and forming mechanism 600 are as follows:

[0122] Flat wire placement: Based on the size and model of the flat wire, select the corresponding mold assembly 620 and place the initially planar "U"-shaped flat wire into the wire feeding slot 6222 of the stationary mold 622. Mold assembly 620 positioning: Start the vertical displacement drive motor 631 to drive the ball screw 632 to rotate, causing the vertical sliding block 633 to move the mold assembly 621 vertically to the predetermined working position. Flat wire bending and forming: Start the bending drive cylinder 641 to drive the mounting slide plate 642 to slide along the vertical slide groove, causing the moving mold 621 to move towards the stationary mold 622. The guide wedge blocks 6211 on the moving mold 621 and the stationary mold 622 wedge-shaped to ensure that the moving mold 621 is accurately aligned with the stationary mold 622. The bending protrusion 6212 of the moving mold 621 bends the flat wire in the wire feeding slot 6222, making it a 3D three-dimensional shape with a bent arc at the top. Safety protection: Throughout the process, the protective plate 652 of the protective component 650 is always supported on the underside of the mold component 620 to ensure the safety of the mold component 620.

[0123] The wire insertion mechanism 700 includes a wire handling assembly 710 for handling flat wires, a transfer assembly 720 for inserting flat wires, a transfer insertion assembly 730 for transferring flat wires from the wire handling assembly 710 to the transfer assembly 720, and a buffer assembly 740 for holding spare flat wires, wherein:

[0124] The transfer insertion assembly 730 is located between the wire handling assembly 710 and the transfer assembly 720; the buffer assembly 740 is located beside the transfer insertion assembly 730; the transfer assembly 720 has a transfer mold 721, which has a plurality of flat wire placement slots 7211 for placing flat wires, and the transfer mold 721 is movable and corresponds to the transfer insertion assembly 730.

[0125] The buffer component 740 includes several wire feeding blocks 741 for placing flat wires. The wire feeding blocks 741 are evenly spaced, providing an orderly placement space for spare flat wires, facilitating management and retrieval. When a shortage of flat wires occurs during production, spare flat wires can be quickly obtained from the buffer component 740, avoiding production interruptions due to insufficient flat wire supply and ensuring the continuity and stability of production.

[0126] The wire handling assembly 710 includes a rotating device, a plurality of wire clamping devices 712, and a driving device 713 for opening the wire clamping devices 712. The plurality of wire clamping devices 712 are mounted on the rotating device, and the output end of the driving device 713 is detachably connected to the wire clamping devices 712.

[0127] The rotating device includes a base 7111, a rotary motor 7112, and a turntable 7113. The rotary motor 7112 is mounted on the base 7111, and the turntable 7113 is mounted on the shaft end of the rotary motor 7112. An arc-shaped track 7114 is provided on the outer wall of the base 7111 for changing the wire clamping device 712 from a vertical state to a horizontal state. The wire clamping device 712 is movably mounted on the edge of the turntable 7113.

[0128] The wire clamping device 712 includes a main body 7121, a wire clamping component 7122 mounted on the main body 7121, and a roller 7123. The roller 7123 rolls and cooperates with the arc-shaped track 7114. The drive device 713 is detachably engaged with the wire clamping component 7122.

[0129] The drive device 713 includes a push block 7131 and a moving drive cylinder 7132 that drives the push block 7131 to move. The push block 7131 is mounted on the shaft end of the moving drive cylinder 7132.

[0130] The wire clamping component 7122 includes two wire clamping claws 71221, a driving member 71222 for opening and closing the two wire clamping claws 71221, and an elastic member for resetting the driving member 71222. The lower ends of the two wire clamping claws 71221 are symmetrically hinged to the upper ends of the driving member 71222 on both sides, and the elastic member abuts between the upper part of the driving member 71222 and the main body 7121.

[0131] The wire clamping device 712 also includes a wire pressing component 7124, which includes a wire pressing support 71241, a wire pressing arm 71242, and a drive arm 71243. The wire pressing support 71241 is mounted on the side wall of the main body 7121. The wire pressing arm 71242 is rotatably hinged to the top of the wire pressing support 71241, and a gear 71244 is provided at the hinge of the wire pressing arm 71242. The drive arm 71243 can be elastically slidably mounted on the side wall of the main body 7121 under the drive of the drive device 713. A rack 71245 is provided on the drive arm 71243 corresponding to the gear 71244, and the rack 71245 meshes with the gear 71244.

[0132] The rotating device can drive multiple wire clamping devices 712 to rotate, realizing the cyclical transport of flat wire and improving transport efficiency. The rolling cooperation between the roller 7123 and the arc-shaped track 7114 ensures that the wire clamping device 712 can change its posture according to a predetermined trajectory. The separable cooperation between the drive device 713 and the wire clamping component 7122 allows the wire clamping component 7122 to perform the function of clamping and releasing flat wire under the action of the drive device 713, making operation flexible and convenient. The moving drive cylinder 7132 drives the push block 7131 to move, and the push block 7131 can dock with the wire clamping component 7122 to drive the wire clamping component 7122. This structure is simple and reliable, and can accurately control the opening and closing action of the wire clamping component 7122, ensuring the accuracy of wire clamping and releasing. The two wire clamping claws 71221 can perform opening and closing actions under the drive of the drive component 71222, thereby clamping and releasing flat wire. The elastic element allows the drive component 71222 to automatically reset when no external force is applied, ensuring the normal working cycle of the wire clamping component 7122 and improving the stability and reliability of the wire clamping. The drive arm 71243 slides elastically under the drive of the drive device 713. Through the meshing of the rack 71245 and the gear 71244, the pressing arm 71242 rotates to perform the pressing operation on the flat wire. This further ensures the stability of the wire clamping, prevents the flat wire from slipping during handling, and improves handling quality.

[0133] The transfer insertion assembly 730 includes a robot arm 731, a longitudinal drive device 732, a vertical drive device 733, and a wire clamping cylinder 734. The longitudinal drive device 732 is installed at the output end of the robot arm 731, the vertical drive device 733 is installed at the output end of the longitudinal drive device 732, and the wire clamping cylinder 734 is installed at the output end of the vertical drive device 733.

[0134] The robotic arm 731 provides flexible operational capabilities. The longitudinal drive device 732 and the vertical drive device 733 can adjust the position of the wire clamping cylinder 734 in the horizontal and vertical directions, respectively, so that the wire clamping cylinder 734 can accurately transfer the flat wire from the wire handling assembly 710 to the transfer mold 721 of the transfer assembly 720. This multi-dimensional motion control improves the accuracy and efficiency of the transfer insertion.

[0135] The transfer assembly 720 also includes a rotary drive device 722 and a transfer drive device 723. The transfer drive device 723 is installed at the output end of the rotary drive device 722, and the transfer module 721 is installed at the output end of the transfer drive device 723.

[0136] The rotary drive device 722 includes a rotary drive motor and a rotating disk, the rotating disk being mounted at the output end of the rotary drive motor; the transfer drive device 723, the longitudinal drive device 732, and the vertical drive device 733 all employ a drive cylinder and a sliding seat, the sliding seat being mounted at the output end of the drive cylinder.

[0137] The transfer assembly 720 also includes a mounting plate 724 and a lifting drive cylinder 725, which is vertically mounted on the mounting plate 724. The transfer mold 721 is mounted on the output end of the lifting drive cylinder 725 and is liftable on the mounting plate 724.

[0138] The rotary drive device 722 can drive the transfer mold 721 to rotate, and the transfer drive device 723 can move the transfer mold 721 within a certain range. The two work together to adjust the position and angle of the transfer mold 721, allowing for better docking with the transfer insertion assembly 730 and achieving accurate insertion operations. The lifting drive cylinder 725 can raise and lower the transfer mold 721 to adapt to different insertion requirements. During the insertion process, the height of the transfer mold 721 is adjusted by the lifting drive cylinder 725 according to the height of the flat wire and the requirements of the insertion position, improving the flexibility and adaptability of the insertion process.

[0139] High-efficiency handling: The rotating device of the wire handling assembly 710 can easily change the wire clamping device 712 from a vertical state to a horizontal state through the arc track 7114, so that the posture of the flat wire can be flexibly adjusted as needed, which facilitates the gripping and transfer of the robot arm 731 and improves the efficiency of flat wire handling.

[0140] Orderly insertion: The transfer component 720 provides an orderly transfer link for the flat wire during insertion. The mobility of the transfer mold 721 and the design of multiple flat wire feeding slots 7211 can better cooperate with the transfer insertion component 730 to perform insertion operations, thereby improving the accuracy and efficiency of insertion.

[0141] Flexible caching: The several evenly spaced wire feeding blocks 741 of the caching component 740 provide reasonable placement space for spare flat wires, making them easy to retrieve when needed and ensuring the continuity of production.

[0142] Precise collaboration: Through reasonable layout and connection methods, the components achieve efficient signal transmission and collaboration, ensuring stable operation of the entire wiring process and improving the quality of flat wire motor assembly.

[0143] The usage method and principle of the 700 wire insertion mechanism for assembling flat wire motors are as follows:

[0144] Wire handling: The rotary motor 7112 drives the turntable 7113 to rotate, and the wire clamping device 712 rotates with the turntable 7113. The roller 7123 rolls on the arc track 7114, changing the wire clamping device 712 from a vertical to a horizontal position. The moving drive cylinder 7132 of the drive device 713 pushes the push block 7131, which engages with the wire clamping component 7122, driving the two clamping claws 71221 to open or close, realizing the clamping and release of the flat wire. At the same time, the drive arm 71243 of the wire pressing component 7124 slides under the drive of the drive device 713. Through the meshing of the rack 71245 and the gear 71244, the wire pressing arm 71242 rotates to perform the wire pressing operation on the flat wire, ensuring the stability of the clamping. Flat wire transfer and insertion: The robotic arm 731 of the transfer insertion assembly 730 grips the flat wire on the wire handling assembly 710. The longitudinal drive device 732 and the vertical drive device 733 adjust the position of the clamping cylinder 734 to transfer the flat wire into the flat wire feeding slot 7211 of the transfer mold 721 in the transfer assembly 720. The rotary drive device 722 and the transfer drive device 723 can adjust the position and angle of the transfer mold 721 to cooperate with the transfer insertion assembly 730 for accurate insertion. The lifting drive cylinder 725 can raise and lower the transfer mold 721 to adapt to different insertion requirements. Spare flat wire buffer: When spare flat wire is needed, it can be taken from the feeding block 741 of the buffer assembly 740 to ensure production continuity.

[0145] The key design feature of this invention is to achieve full automation of wire feeding, paint stripping, wire pulling, feeding, 2D / 3D forming, and wire insertion by employing a wire feeding mechanism, a paint stripping mechanism, a wire pulling mechanism, a dual-channel feeding mechanism, a flat wire 2D forming mechanism, a flat wire 3D bending forming mechanism, and a wire insertion mechanism. This improves production efficiency and product consistency, reduces manual intervention, and ensures forming accuracy and wire insertion reliability. The wire feeding mechanism guarantees the quality of the flat wire, the paint stripping mechanism improves paint stripping efficiency and the quality of the working environment, the wire pulling mechanism enables precise wire pulling and cutting operations, and the dual-channel feeding mechanism enhances feeding efficiency. The flat wire 2D forming mechanism utilizes a mold device, a lifting drive assembly, a forming drive assembly, and an anti-drop assembly to achieve efficient and accurate 2D forming of the flat wire and ensure equipment safety. The flat wire 3D bending forming mechanism achieves efficient and accurate 3D forming of the flat wire through the coordinated work of the mold assembly, vertical displacement drive assembly, bending drive assembly, and protective assembly. Safety assurance for bending and forming and mold assembly operation; the wire handling component, transfer component, transfer insertion component and buffer component in the wire insertion mechanism automatically realize the handling, transfer insertion and transfer insertion of flat wire, making the whole process of flat wire from handling to insertion smoother, improving insertion efficiency and reducing labor costs.

[0146] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation on the technical scope of the present invention. Therefore, any minor modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A flat wire electric milling device, characterized in that: The device includes a wire feeding mechanism for placing flat wire, a stripping mechanism for stripping the coating from the flat wire, a wire pulling mechanism for pulling the flat wire, a dual-channel feeding mechanism for forward feeding of the flat wire, a 2D forming mechanism for 2D forming of the flat wire, a 3D bending forming mechanism for 3D bending of the flat wire, and a wire insertion mechanism for inserting the flat wire. The flat wire passes sequentially through the wire feeding mechanism, the stripping mechanism, the wire pulling mechanism, the dual-channel feeding mechanism, the 2D forming mechanism, the 3D bending forming mechanism, and the insertion mechanism. The 3D bending forming mechanism includes a support frame, a mold assembly for 3D bending of the flat wire, a vertical displacement drive assembly for driving the vertical movement of the mold assembly, a bending drive assembly for driving the mold assembly to bend the flat wire, and a protective assembly for protecting the mold assembly. The vertical displacement drive assembly is mounted on the support frame. The mold assembly is mounted on the output end of the vertical displacement drive assembly. The mold assembly is liftably mounted on the support frame. The output end of the protective assembly supports the lower side of the mold assembly. The flat wire 2D forming mechanism includes a mold device for placing and forming the flat wire, a lifting drive assembly for driving the mold device to rise and fall, a forming drive assembly for driving the mold device to form the flat wire, and an anti-fall assembly for preventing the mold device from falling. The mold device is installed at the output end of the lifting drive assembly; the output end of the forming drive assembly is detachably connected to the mold device; and the output end of the anti-fall assembly is supported on the lower side of the mold device. The mold device includes an upper mold and a lower mold. The upper mold is slidably connected above the lower mold. The lower mold has a forming block. The upper mold has a forming opening that matches the forming block. The upper mold can slidably bend the flat wire between the forming block and the forming opening. The forming drive assembly includes a forming drive device and a push slider. The push slider is installed at the output end of the forming drive device and can be detachably abutted against the upper mold.

2. The flat wire electric milling equipment according to claim 1, characterized in that: The mold assembly has a moving mold and a stationary mold. The moving mold is connected to the output end of the bending drive assembly, which drives the moving mold to move and dock with the stationary mold. The mold assembly consists of several groups, with several moving molds and several stationary molds corresponding one-to-one in the several groups. The several moving molds and several stationary molds are vertically installed at the output end of the vertical displacement drive assembly.

3. The flat wire electric milling equipment according to claim 2, characterized in that: The vertical displacement drive assembly includes a vertical displacement drive motor, a ball screw, and a vertical slide block. The ball screw is installed at the output end of the vertical displacement drive motor and rotates with the vertical slide block. Several sets of mold assemblies are installed on the vertical slide block. The bending drive assembly includes a bending drive cylinder and a mounting plate. The bending drive cylinder is vertically installed on the vertical slide block, and the mounting plate is installed at the output end of the bending drive cylinder. The mounting plate is slidably located on the vertical slide block, and the moving mold is disposed on the mounting plate.

4. The flat wire electric milling equipment according to claim 1, characterized in that: The insertion mechanism includes a wire handling assembly for transporting flat wires, a transfer assembly for inserting flat wires, a transfer insertion assembly for transferring flat wires from the wire handling assembly to the transfer assembly, and a buffer assembly for placing spare flat wires. The transfer insertion assembly is located between the wire handling assembly and the transfer assembly. The buffer assembly is located beside the transfer insertion assembly. The transfer assembly has a transfer mold with several flat wire slots for placing flat wires. The transfer mold is movable and corresponds to the transfer insertion assembly.

5. The flat wire electric milling equipment according to claim 4, characterized in that: The transfer assembly also includes a rotary drive device and a transfer drive device. The transfer drive device is installed at the output end of the rotary drive device, and the transfer mold is installed at the output end of the transfer drive device. The transfer assembly also includes a mounting plate and a lifting drive cylinder. The lifting drive cylinder is vertically mounted on the mounting plate, and the transfer mold is installed at the output end of the lifting drive cylinder. The transfer mold is liftable and detachable on the mounting plate.

6. The flat wire electric milling equipment according to claim 1, characterized in that: The wire feeding mechanism includes a wire feeding reel and several straightening rollers. The straightening rollers are arranged in two rows, and a straightening channel is formed between the two rows of straightening rollers for the flat wire to pass through. The flat wire is fed by the wire feeding reel and straightened by passing through the straightening channel.

7. The flat wire electric milling equipment according to claim 1, characterized in that: The paint stripping mechanism includes a threading channel for the flat wire to pass through and a paint stripping device for stripping the paint from the flat wire. The flat wire passes through the threading channel, and the paint stripping device faces the flat wire. The paint stripping device is a paint stripping laser, and there are four paint stripping lasers, each facing one of the four sides of the square-shaped flat wire. The threading channel is provided with a smoke extraction pipe for smoke extraction, and the smoke extraction pipe is connected to a smoke extractor.

8. The flat wire electric milling equipment according to claim 1, characterized in that: The wire pulling mechanism includes a wire pulling assembly and a wire cutting assembly for cutting flat wires. The output end of the wire pulling assembly is movably corresponding to the wire cutting assembly. The wire pulling assembly includes a support base, a wire pulling drive motor, a toothed wheel, a toothed strip, a sliding base, and a clamping cylinder for clamping the wire. The toothed strip is laterally fastened to the support base. The toothed wheel is installed at the output end of the wire pulling drive motor and meshes with the toothed strip. The wire pulling drive motor is fastened to the sliding base, and the clamping cylinder is installed on the sliding base.

9. The flat wire electric milling equipment according to claim 1, characterized in that: The dual-channel feeding mechanism includes a feeding assembly for conveying flat wires in two channels, a first pushing assembly for pushing the flat wires on the feeding assembly along one of the channel directions, a second pushing assembly for pushing the flat wires on the feeding assembly along the other channel direction, a first picking assembly for gripping the flat wires pushed by the first pushing assembly, and a second picking assembly for gripping the flat wires pushed by the second pushing assembly. The feeding assembly has a first feeding plate and a second feeding plate. The first feeding plate is movably located below the first pushing assembly, and the second feeding plate is movably located below the second pushing assembly. The first picking assembly is located beside the first pushing assembly, and the second picking assembly is located beside the second pushing assembly.

10. A method for manufacturing flat wire using an electric wire-making device as described in any one of claims 1-9, characterized in that: Includes the following steps: First, the flat wire is located on the wire feeding mechanism and is pulled forward by the wire pulling mechanism to achieve wire feeding; Second, the paint stripping mechanism strips the paint from the areas of the flat wire that need to be stripped. Third, the wire pulling component of the wire pulling mechanism pulls the flat wire forward. When the flat wire is pulled to a certain distance, the wire cutting component cuts the flat wire to obtain a flat wire in the form of segments of a certain distance. Fourth, the dual-channel feeding mechanism receives the cut flat wire and uses a dual-channel feeding method for the flat wire; Fifth, the dual-channel feeding mechanism feeds the flat wire to the flat wire 2D forming mechanism, which performs 2D forming on the flat wire; Sixth, the flat wire is fed to the flat wire 3D bending and forming mechanism, which performs 3D bending and forming on the flat wire; Seventh, the insertion mechanism inserts the formed flat wire into the transfer component.

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