Stator assembly torsion head process debugging tool and method, stator trial-manufacturing method and vehicle

Abstract

The invention discloses a stator assembly torsion head process debugging tool and method, a stator trial-manufacturing method and a vehicle, the stator assembly torsion head process debugging tool comprises an annular process iron core, the process iron core is provided with a plurality of slots, the plurality of slots are circumferentially arranged around the center of the process iron core, and each slot respectively penetrates through the upper surface and the lower surface of the process iron core; a center hole penetrating through the upper surface and the lower surface is formed in the center of the step cover plate, the step cover plate is arranged above the process iron core and is coaxial with the process iron core, a first annular groove and a second annular groove are formed in the hole wall of the center hole, the first annular groove is located above the second annular groove, and the diameter of the first annular groove is smaller than that of the second annular groove; the lower end of the second annular groove is communicated with the slot; and the process gasket is detachably connected between the process iron core and the step cover plate. According to the invention, the problems of long trial-manufacture period and high cost of the flat wire motor stator can be solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of motor stator debugging, in particular to a stator assembly head twisting process debugging tool and method, a stator trial production method and a vehicle. BACKGROUND

[0002] With the rapid development of pure electric passenger cars, the performance requirements of electric motors are becoming higher and higher. Because flat wire motors have the advantages of small size, high power density and fast response speed, they have become the mainstream development direction of pure electric passenger car motors. In order to improve the performance of flat wire motors, the stator structure and parameters of flat wire motors need to be continuously optimized. The optimized flat wire motor stator needs to be tested by a prototype to detect performance parameters. Therefore, the demand for flat wire motor stator testing is huge.

[0003] In related technologies, the main process of the flat wire motor stator is flat wire forming, core processing, wire insertion, flaring, head twisting and welding. The traditional trial production process needs to be trial-produced step by step according to the above processes. In the head twisting process, the tool and process parameters need to be verified and adjusted multiple times. Moreover, the head twisting process needs to wait for the flat wire to be formed, inserted into the core and flared before verification. After verification, the deformed flat wire cannot be used again and needs to be removed and re-inserted for process verification. Each time, the inserted flat wire is a full-process finished product, which causes serious material waste. In addition, in order to ensure the firm fixation of the flat wire, all the flat wires need to be inserted into the core, which prolongs the wire insertion process and makes the flat wire motor trial production cycle long and the cost high. SUMMARY

[0004] The present application aims to solve at least one of the technical problems existing in the prior art. To this end, the present application provides a stator assembly head twisting process debugging tool and method, a stator trial production method and a vehicle, which can solve the problems of long trial production cycle and high cost of flat wire motor stator.

[0005] The solution to the technical problem of the present application is as follows: In a first aspect, a stator assembly head twisting process debugging tool is provided, comprising: A process core in the shape of a ring is provided with a plurality of insertion slots arranged around the center circumference of the process core, and each insertion slot penetrates the upper and lower surfaces of the process core; A stepped cover plate is provided with a center hole penetrating the upper and lower surfaces, and the stepped cover plate is arranged above the process core and coaxially arranged with the process core. The hole wall of the center hole is provided with a first annular groove and a second annular groove. The first annular groove is located above the second annular groove, and the diameter of the first annular groove is smaller than the diameter of the second annular groove. The lower end of the second annular groove is in communication with the insertion slot; A process gasket is detachably connected between the process core and the stepped cover plate.

[0006] The present application has at least the following advantages: the stator assembly head twisting process debugging is performed using the head twisting process debugging tool, the head twisting process debugging tool of the stator assembly adds a stepped cover plate at the non-head twisting end of the flat wire, so that the same length of flat wire can have different lengths of extension in the head twisting section, the types of flat wire blanking sizes are reduced, the trial production cost is reduced, and the efficiency is improved while reducing the wire insertion errors. Moreover, the process gasket is detachably connected between the process core and the stepped cover plate, by replacing the process gasket with different thickness, the process parameters of the flat wire extension length can be uniformly adjusted, thereby improving the efficiency of process verification and shortening the trial production cycle of the flat wire motor stator.

[0007] As a further improvement of the above technical solution, the process core and the stepped cover plate are connected by bolts.

[0008] As a further improvement of the above technical solution, the bolts are provided in plurality, and the plurality of bolts are arranged uniformly in the circumferential direction of the center axis of the stepped cover plate and located outside the second annular groove.

[0009] In a second aspect, a stator assembly head twisting process debugging method is provided, comprising the following steps: A stator assembly head twisting process debugging tool is prepared: the stator assembly head twisting process debugging tool comprises a process core, a stepped cover plate and a process gasket, the process core is annular, the process core is provided with a plurality of insertion slots, the plurality of insertion slots are arranged around the center circumference of the process core, each insertion slot penetrates the upper and lower surfaces of the process core, and the insertion slots are used for inserting the hairpin wire; the center of the stepped cover plate is provided with a center hole penetrating the upper and lower surfaces, the stepped cover plate is arranged above the process core and coaxially arranged with the process core, the hole wall of the center hole is provided with a first annular groove and a second annular groove, the first annular groove is located above the second annular groove, the diameter of the first annular groove is smaller than the diameter of the second annular groove, and the lower end of the second annular groove is in communication with the insertion slot; the process gasket is detachably connected between the process core and the stepped cover plate; Head twisting process verification; Determination of head twisting process parameters.

[0010] As a further improvement of the above technical solution, the step of preparing the stator assembly head twisting process debugging tool comprises the following steps: Design and process the process core; The process step difference of each layer of hairpin wire before head twisting is calculated, and the process step difference is the length difference of each group of flat wire extending the stator core; The stepped cover plate is designed and processed according to the process step difference. Connect the process core and the stepped cover plate.

[0011] As a further improvement to the above technical solution, the step of connecting the process core and the stepped cover plate includes: Select a process shim of appropriate thickness according to the length of the flat wire extending out of the stator core, and place the process shim between the process core and the stepped cover plate; The process core and the stepped cover plate are connected by bolts.

[0012] As a further improvement to the above technical solution, the height of the process core is 1 / 3 of that of the stator core.

[0013] As a further improvement to the above technical solution, the width of the slot along the radial direction of the process core is equal to the thickness of two layers of hairpin wire.

[0014] Thirdly, a stator trial manufacturing method is proposed, including the following steps: Flat wire forming; Iron core processing; Plug in the cable; Flaring; Twisting: During the flat wire forming step and / or core processing step, the stator assembly twisting process debugging method described in any of the technical solutions in the second aspect is used to determine the twisting process parameters; after completing the flat wire forming step and core processing step, the twisting process trial is completed according to the twisting process parameters; welding.

[0015] Fourthly, a vehicle is proposed, including a flat wire motor stator, said flat wire motor stator being manufactured using the stator prototyping method described in any one of the technical solutions in the third aspect.

[0016] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly explained below. Obviously, the described drawings are only a part of the embodiments of the present invention, and not all of them. Those skilled in the art can obtain other design schemes and drawings based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the overall structure of the stator assembly twisting head process debugging tooling according to an embodiment of the present invention; Figure 2is an exploded structural schematic view of a stator assembly head twisting process debugging tooling of an embodiment of the present application; Figure 3 is a cross-sectional view of a stepped cover plate of an embodiment of the present application; Figure 4 is a flowchart of a stator assembly head twisting process debugging method of an embodiment of the present application; Figure 5 is Figure 4 is a refinement flowchart of step S100 in Figure 6 is Figure 5 is a refinement flowchart of step S140 in

[0019] Reference signs: 101, process core; 102, stepped cover plate; 103, bolt; 104, first annular groove; 105, second annular groove. DETAILED DESCRIPTION

[0020] Embodiments of the present application will be described in detail below, examples of which are shown in the drawings, wherein the same or similar reference signs represent the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the drawings are exemplary, only for explaining the present application, and cannot be understood as limiting the present application.

[0021] In the description of the present application, if the orientation description, such as the orientation or position relationship indicated by up, down, front, back, left, right, etc. is based on the orientation or position relationship shown in the drawings, it is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the device or element indicated must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0022] In the description of the present application, the meaning of several is one or more, the meaning of multiple is more than two, greater than, less than, more than, etc. are understood as not including the number, above, below, etc. are understood as including the number. If it is described as first, second, it is only for the purpose of distinguishing technical features, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of indicated technical features or the order of indicated technical features.

[0023] In the description of the present application, unless otherwise explicitly limited, the words such as setting, installing, connecting, etc. should be broadly understood, and the person skilled in the art can reasonably determine the specific meaning of the above words in the present application in combination with the specific content of the technical solution.

[0024] Obviously, the described embodiments are only part of the embodiments of the present application, not all the embodiments, and other embodiments obtained by those skilled in the art based on the embodiments of the present application without creative labor are within the protection scope of the present application. Various technical features in the present application can be combined with each other as long as they are not contradictory.

[0025] In the first aspect, with reference to Figure 1 、 Figure 2 and Figure 3 , the embodiment of the present application provides a stator assembly head twisting process debugging tool, which comprises a process core 101, a stepped cover plate 102 and a process gasket. The use of the stator assembly head twisting process debugging tool for stator assembly head twisting process debugging can shorten the time of the entire flat wire motor stator agent and improve the production and processing efficiency.

[0026] In the embodiment, the process core 101 is annular, the process core 101 is provided with a plurality of insertion slots, the plurality of insertion slots are arranged around the center circumference of the process core 101, and each insertion slot penetrates the upper and lower surfaces of the process core 101. The center of the stepped cover plate 102 is provided with a center hole, the center hole penetrates the upper and lower surfaces of the stepped cover plate 102, the stepped cover plate 102 is arranged above the process core 101, and the process core 101 and the stepped cover plate 102 are coaxially arranged, the hole wall of the center hole is provided with a first annular groove 104 and a second annular groove 105, the first annular groove 104 is located above the second annular groove 105, the diameter of the first annular groove 104 is smaller than the diameter of the second annular groove 105, and the lower end of the second annular groove 105 is in communication with the insertion slot. The process gasket is detachably connected at the position between the process core 101 and the stepped cover plate 102.

[0027] It can be understood that the thickness of the process gasket can be adjusted and replaced according to actual needs, In the current flat wire motor trial production field, the stator assembly trial production cycle is long and the cost is high, and there are the following two main problems: first, the types of the hairpin wire are various, for example, for an 8-layer 48-slot stator, the types of the hairpin wire are 9-10, and the number of the hairpin wire is about 198. The forming process of the hairpin wire is generally divided into straight line blanking, 2D bending and 3D forming. The trial production workload of the flat wire forming is relatively large, and the debugging cycle is long. The wire insertion is manual in the trial production process, and different specifications of the hairpin wire need to be inserted into the corresponding core slot according to the design requirements. At this time, the hairpin wire is a debugging piece, the accuracy of the wire type is poor, the consistency is low, and the hairpin wire is prone to jamming when inserted into the core, which makes the insertion of the 198 hairpin wires difficult, the workload is large, and the debugging cycle is long. After the stator with the inserted wire is verified by the head twisting process, the hairpin wire deforms at the twisted end. In order to adjust the process parameters and re-verify, the deformed end of the hairpin wire must be damaged to replace the new hairpin wire, which is time-consuming and laborious. Second, the length of a hairpin wire is about 400 mm, and the entire hairpin wire needs to be scrapped each time, resulting in serious material waste.

[0028] The stator assembly head twisting process debugging tool of the present embodiment can make the head twisting process independent from the original process flow, and does not need to wait until the flat wire forming and core processing and other process verifications are completed before proceeding, thereby shortening the time of the entire process flow. At the same time, the stator assembly head twisting process debugging tool can reduce the difficulty of wire insertion and replacement. The "process hairpin wire" only needs to be half the size of the original hairpin wire blanking size, which greatly reduces the debugging cycle and cost.

[0029] It can be understood that the stator assembly head twisting process debugging tool of the present embodiment increases the stepped cover plate 102 at the non-twisted end, so that the same length of flat wire can achieve different extension lengths, reduce the types of flat wire blanking size, improve efficiency and reduce wire insertion errors.

[0030] It can be understood that in the stepped cover plate 102, the process step difference formed by the first annular groove 104 and the second annular groove 105 is the length difference of each group of flat wires extending out of the stator core. The height of the process core 101 can be one third of the normal core height, which can reduce the blanking length of the debugging flat wire and reduce the material cost.

[0031] In some embodiments, the process core 101 and the stepped cover plate 102 are connected by bolts 103. The bolt 103 connection structure is simple, convenient and fast to disassemble and assemble. By directly adding process gaskets of different thicknesses between the process core 101 and the stepped cover plate 102, the process parameters of the flat wire extension length can be uniformly adjusted, thereby improving the efficiency of process verification.

[0032] It can be understood that the process gasket can be sleeved outside or inside the circumference formed by the plurality of insertion slot arrangements.

[0033] In some embodiments, the bolts 103 used to connect the process core 101 and the stepped cover plate 102 are provided in four, and the four bolts 103 are arranged evenly in the circumferential direction of the center axis of the stepped cover plate 102, and are arranged at the outer edge of the stepped cover plate 102, i.e. outside the second annular groove 105. In this way, the bolts 103 can avoid interfering with the first annular groove 104 and the second annular groove 105, and can increase the connection area of the stepped cover plate 102 and the bolts 103, and improve the locking strength of the bolts 103 on the stepped cover plate 102 and the process core 101.

[0034] Of course, the bolts 103 used to connect the process core 101 and the stepped cover plate 102 can also be provided in other numbers, such as two, three, five, etc., which are not specifically limited here.

[0035] It can be understood that the process gasket can also be provided with a hole corresponding to the bolt 103, and when the process gasket is installed, the bolt 103 can directly pass through the corresponding hole to fix the process gasket. Of course, the process gasket can also be adjusted in diameter to avoid the arrangement of the bolt 103.

[0036] In a second aspect, the embodiment of the present application also provides a stator assembly head twisting process debugging method. The stator assembly head twisting process debugging method can shorten the time of the entire process flow, and the stator assembly head twisting process debugging tool can reduce the difficulty of wire insertion and replacement of flat wires.

[0037] The stator assembly head twisting process debugging method includes steps S100, S200 and S300, which will be described in detail below with reference to the accompanying drawings. Figure 4 .

[0038] Step S100, preparing a stator assembly head twisting process debugging tool.

[0039] It is understood that the stator assembly twisting process debugging fixture is the stator assembly twisting process debugging fixture proposed in any embodiment of the first aspect, which includes a process core 101, a stepped cover plate 102, and a process gasket. The process core 101 is annular and has multiple slots arranged around the central circumference of the process core 101. Each slot penetrates the upper and lower surfaces of the process core 101 and is used to insert a hairpin. The stepped cover plate 102 has a central hole penetrating the upper and lower surfaces. The stepped cover plate 102 is located above the process core 101 and coaxially arranged with the process core 101. The wall of the central hole has a first annular groove 104 and a second annular groove 105. The first annular groove 104 is located above the second annular groove 105, and the diameter of the first annular groove 104 is smaller than the diameter of the second annular groove 105. The lower end of the second annular groove 105 communicates with the slot. The process gasket is detachably connected between the process core 101 and the stepped cover plate 102.

[0040] Step S200, Twisting process verification. The twisting process is verified individually for each group of flat wires, thereby reducing the workload of wire changing and insertion, and improving work efficiency.

[0041] Step S300: Determine the twisting process parameters.

[0042] In some embodiments, step S100 specifically includes steps S110, S120, S130, and S140, see [link to previous steps]. Figure 5 .

[0043] Step S110: Design and manufacture the process core 101. In some embodiments, the process core 101 is manufactured by wire cutting of aluminum blocks.

[0044] Step S120: Calculate the process step difference for each layer of hairpin wire before the twist. The process step difference is the length difference of each group of flat wires extending out of the stator core. Specifically, calculate the unfolded length of the center layer at the twist end of each type of hairpin wire using design data to obtain the process step difference for each layer of hairpin wire before the twist.

[0045] Step S130: Design and process the stepped cover plate 102 according to the process step difference. In some embodiments, the stepped cover plate 102 is processed by 3D printing.

[0046] Step S140, connect the process core 101 and the stepped cover plate 102. It can be understood that after the process core 101 is connected with the stepped cover plate 102, the stator assembly head twisting process debugging tool is obtained, which can make the same length of flat wire in different slots, and the overhanging amount at the head twisting end has a step difference, so as to meet the process step difference calculated in the above step, and the flat wire overhanging length can be adjusted as a whole, which is convenient for adjusting and verifying the head twisting process parameters. It can be understood that using the stator assembly head twisting process debugging tool for debugging does not need to insert the complete hairpin wire, so as to reduce the waste of flat wire and reduce the cost of process debugging.

[0047] In some embodiments, step S140 specifically includes step S141 and step S142, with reference to Figure 6 .

[0048] Step S141, according to the length of the flat wire overhanging the stator core, select a process gasket with a corresponding thickness, and place the process gasket between the process core 101 and the stepped cover plate 102. It can be understood that by adjusting the thickness of the corresponding process gasket, the length of the flat wire overhanging the core can be changed without changing the length of the flat wire blank, which meets the requirement of changing the process parameters, improves the verification efficiency of the head twisting process, shortens the trial production cycle, and thus determines the most suitable head twisting process parameters.

[0049] Step S142, use the bolt 103 to connect the process core 101 and the stepped cover plate 102. After connecting the process core 101 and the stepped cover plate 102 through the bolt 103, the stator assembly head twisting process debugging tool that meets the process parameter requirement is obtained, so as to facilitate subsequent adjustment and improve verification efficiency.

[0050] In some embodiments, a plurality of bolts 103 are used to connect the process core 101 and the stepped cover plate 102, and the plurality of bolts 103 are arranged uniformly in the circumferential direction of the center axis of the stepped cover plate 102 and are arranged at the outer edge of the stepped cover plate 102, i.e. outside the second annular groove 105. In this way, the interference of the bolt 103 with the first annular groove 104 and the second annular groove 105 can be avoided, and the connection area of the stepped cover plate 102 and the bolt 103 can be increased, and the locking strength of the bolt 103 to the stepped cover plate 102 and the process core 101 can be improved. It can be understood that when the stepped cover plate 102 and the process core 101 are processed, the hole and the screw hole for the bolt 103 to pass through and connect should be reserved.

[0051] In some embodiments, the height of the process core 101 is set to one third of the height of the stator core. In this way, the length of the flat wire for debugging can be reduced, and the material cost can be reduced.

[0052] In some embodiments, the width of the slot along the radial direction of the process core is the thickness of the two-layer card wire, i.e. the thickness of the two-layer flat wire. It is ensured that the two-layer flat wire can be smoothly inserted into the process core 101 without shifting, and the replacement is convenient.

[0053] In a third aspect, the embodiment of the present application provides a stator trial manufacturing method, which comprises a flat wire forming step, a core processing step, a wire inserting step, a flaring step, a head twisting step and a welding step.

[0054] In the head twisting step, the head twisting process parameter is determined by using the stator assembly head twisting process debugging method of any one of the embodiments of the second aspect during the flat wire forming step and / or the core processing step. After the flat wire forming step and the core processing step are completed, the head twisting process trial manufacturing is completed according to the head twisting process parameter.

[0055] Through the stator trial manufacturing method of the embodiment, the head twisting process verification work can be carried out in advance when the flat wire forming and core processing processes are not completed. By adjusting the corresponding stator assembly head twisting process debugging tooling, the length of the flat wire extending out of the process core 101 can be changed without changing the length of the flat wire blank, the requirement of changing the process parameter is met, the head twisting process verification efficiency is improved, the trial manufacturing period is shortened, and the most suitable head twisting process parameter is determined. After the flat wire debugging and the core processing are completed, the head twisting process trial manufacturing is quickly completed.

[0056] In a fourth aspect, the embodiment of the present application provides a vehicle, which comprises a flat wire motor stator manufactured by the stator trial manufacturing method of the third aspect. Since the flat wire motor stator is manufactured by the stator trial manufacturing method of the third aspect, the production and processing period is short, and the debugging cost is low, so that the production period of the vehicle can be shortened, and the production cost can be reduced.

[0057] It can be understood that the vehicle proposed in the embodiment can be a private car, such as a sedan, an SUV, an MPV or a pickup truck, etc. The vehicle can also be an operating vehicle, such as a van, a bus, a small truck or a large trailer, etc. The vehicle is a new energy vehicle, which can be a hybrid vehicle or a pure electric vehicle.

[0058] The preferred embodiments of the present application are specifically described above, but the present application is not limited to the above-mentioned embodiments. Those skilled in the art can make various equivalent modifications or replacements without departing from the spirit of the present application, and these equivalent modifications or replacements are all included in the scope defined by the claims of the present application.

Claims

1. A stator assembly torsion head process debugging fixture, characterized in that, include: The process core is ring-shaped and has multiple slots arranged around the central circumference of the process core. Each slot penetrates the upper and lower surfaces of the process core. A stepped cover plate, wherein the center of the stepped cover plate has a central hole penetrating through the upper and lower surfaces, the stepped cover plate is disposed above the process core and coaxially arranged with the process core, the hole wall of the central hole has a first annular groove and a second annular groove, the first annular groove is located above the second annular groove, the diameter of the first annular groove is smaller than the diameter of the second annular groove, and the lower end of the second annular groove communicates with the slot. A process gasket is detachably connected between the process core and the stepped cover plate.

2. The stator assembly torsion head process debugging fixture according to claim 1, characterized in that, The process core and the stepped cover plate are connected by bolts.

3. The stator assembly torsion head process debugging fixture according to claim 2, characterized in that, The bolts are provided in multiple quantities, and the multiple bolts are evenly arranged circumferentially around the central axis of the stepped cover plate and located outside the second annular groove.

4. A method for adjusting the torsion head process of a stator assembly, characterized in that, Includes the following steps: Preparation of stator assembly toggle process debugging fixture: The stator assembly toggle process debugging fixture includes a process core, a stepped cover plate, and a process gasket. The process core is annular and has multiple slots arranged around the central circumference of the process core. Each slot penetrates the upper and lower surfaces of the process core and is used to insert a hairpin. The stepped cover plate has a central hole penetrating the upper and lower surfaces. The stepped cover plate is positioned above the process core and coaxially with it. The wall of the central hole has a first annular groove and a second annular groove. The first annular groove is located above the second annular groove, and its diameter is smaller than that of the second annular groove. The lower end of the second annular groove communicates with the slot. The process gasket is detachably connected between the process core and the stepped cover plate. Verification of the toggle head process; Determine the twisting process parameters.

5. The stator assembly torsion head debugging method according to claim 4, characterized in that, The steps for preparing the stator assembly twisting head process debugging fixture include the following steps: Design and manufacture the process core; The process step difference of each layer of hairpin wire before the twist is calculated. The process step difference is the difference in the length of each group of flat wires extending out of the stator core. The stepped cover plate is designed and manufactured according to the aforementioned process step difference; Connect the process core and the stepped cover plate.

6. The stator assembly torsion head debugging method according to claim 5, characterized in that, The step of connecting the process core and the stepped cover plate includes: Select a process shim of appropriate thickness according to the length of the flat wire extending out of the stator core, and place the process shim between the process core and the stepped cover plate; The process core and the stepped cover plate are connected by bolts.

7. The stator assembly torsion head debugging method according to claim 5, characterized in that, The height of the process core is 1 / 3 of that of the stator core.

8. The stator assembly torsion head debugging method according to claim 5, characterized in that, The width of the slot along the radial direction of the process core is equal to the thickness of two layers of card wire.

9. A method for stator trial production, characterized in that, Includes the following steps: Flat wire forming; Iron core processing; Plug in the cable; Flaring; Twisting: During the flat wire forming step and / or core processing step, the stator assembly twisting process debugging method as described in any one of claims 3 to 8 is used to determine the twisting process parameters; after completing the flat wire forming step and core processing step, the twisting process trial is completed according to the twisting process parameters; welding.

10. A vehicle, characterized in that, It includes a flat wire motor stator, which is manufactured using the stator prototyping method as described in claim 9.

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