Card issuing line 3D forming equipment and forming method

Abstract

The invention discloses a card issuing line 3D forming device and method. The device comprises a conveying mechanism, a feeding mechanism, a cross-layer forming mechanism, a splitting and pulling forming mechanism and a discharging mechanism, and the conveying mechanism controls a tool to circulate among all stations; the feeding mechanism achieves variable-diameter supporting of the card issuing line and orderly discharging and feeding. The cross-layer forming mechanism is used for performing elevation angle and S-bend step-by-step forming on the card issuing line; the splitting and pulling forming mechanism achieves top radian forming of the card issuing line through multi-axis linkage. And the discharging mechanism is used for taking out and collecting the card issuing line. The equipment does not need a special stamping die, reduces the production cost, improves the remodeling flexibility, avoids the damage of insulating paint, has the advantages of high automation degree and strong universality, effectively solves the technical problems of high cost, poor flexibility and easy damage of insulation in the stamping forming of a traditional die, and is suitable for the 3D forming processing of the hairpin wire of the flat wire motor.

Description

Technical Field

[0001] This invention relates to motor manufacturing equipment technology, and in particular to a hairpin 3D forming equipment and forming method. Background Technology

[0002] The global automotive industry is rapidly moving towards electrification, and the drive motor, as a core component of electric vehicles, directly determines the competitiveness of the entire vehicle through its performance and cost. Hairpin windings in flat wire motors have become industry standard due to their high slot fill factor, excellent heat dissipation, and compact structure. Hairpin 3D forming is the most technologically advanced and critical process in flat wire motor manufacturing, directly impacting motor performance and production efficiency.

[0003] Existing hairpin lines mainly include upward angle forming, S-bend forming, and split forming structures. Figure 1 Most of these technologies use integrated die stamping, but this approach has the following prominent problems:

[0004] High cost and poor flexibility: Each type of wire requires a dedicated stamping die, and one motor often requires multiple sets of dies; when changing products, the entire set of dies must be replaced, which not only results in high costs for purchasing and repairing dies, but also takes a long time to change products, seriously affecting the production cycle and project progress; for example, a Chinese utility model patent discloses an automatic jig-changing hairpin wire forming system (CN219875425U), which replaces the corresponding jig for different models of hairpin wire.

[0005] Easily damages the insulation layer: During the stamping process, the hard contact between the mold and the surface of the copper wire can easily scratch the insulating varnish, leading to potential hazards in motor operation and reducing the product quality pass rate.

[0006] Insufficient versatility: Dedicated molds are only compatible with specific line types and cannot be used with hairpin lines of different leg spacing and curvature requirements, making it difficult to meet the production needs of multiple varieties and small batches.

[0007] The core reason for the above problems is that traditional stamping relies on a "one-to-one" dedicated mold, and the forming method is one-time rigid extrusion. It lacks modular adjustment capabilities and flexible processing space, which cannot adapt to the diverse forming needs of hair clips, and cannot avoid insulation damage caused by mechanical contact. Summary of the Invention

[0008] To address the problems of high cost, poor flexibility, easy damage to insulation, and insufficient versatility in existing mold stamping technology, this invention provides a 3D forming equipment and method for hair clips. Through modular design and step-by-step forming process, it achieves flexible, efficient, and high-quality forming of hair clips, reduces production costs, and improves equipment versatility.

[0009] To achieve the above and other related objectives, the technical solution provided by this invention is: a 3D forming device for hair clips, comprising a conveying mechanism, a feeding mechanism, a cross-layer forming mechanism, a splitting forming mechanism, and a discharging mechanism. The conveying mechanism controls the tooling for clamping hair clips to circulate between the feeding station, the cross-layer forming station, the splitting forming station, and the discharging station. The feeding mechanism is correspondingly arranged with the feeding station and is used to deliver the hair clips to the conveying mechanism. The cross-layer forming mechanism is correspondingly arranged with the cross-layer forming station and is used to perform step-by-step forming of the hair clips at an elevation angle and an S-bend. The splitting forming mechanism is correspondingly arranged with the splitting forming station and is used to perform splitting forming of the hair clips. The discharging mechanism is correspondingly arranged with the discharging station and is used to remove the hair clips from the conveying mechanism.

[0010] The preferred technical solution is as follows: the conveying mechanism adopts a magnetic levitation conveyor chain, including a circular track and magnetically levitated sliders slidably mounted on the circular track, each magnetically levitated slider being provided with the tooling; the tooling includes a platform, sliders, hook one, hook two, connecting rod one, connecting rod two, a return spring, an actuating rod, and a limiting plate; the platform has an assembly cavity, the sliders are slidably disposed in the assembly cavity, the actuating rod is disposed along the sliding direction of the sliders and one end is fixedly connected to the sliders, the other end extends out of the assembly cavity; the return spring is disposed along the sliding direction of the sliders. In the assembly cavity, one end of the spring abuts against the slider, and the other end abuts against the assembly cavity; hook one and hook two have the same structure and are both mounted in the assembly cavity; one end of connecting rod one is hinged to the slider, and the other end is hinged to the tail end of hook one; one end of connecting rod two is hinged to the slider, and the other end is hinged to the tail end of hook two; hook one and hook two are arranged opposite to each other to form a clamping structure for clamping or releasing one leg of the hairpin; the limiting plate is fixed on the platform and is used to limit the swing range of the other leg of the hairpin.

[0011] The preferred technical solution is as follows: the feeding mechanism includes a mounting frame and a variable diameter guiding module, a pressing module, a cutting module, a picking module, and an actuation module 1 mounted on the mounting frame. The variable diameter guiding module achieves variable diameter support and guiding based on the distance between the legs on both sides of the hairpin wire. The pressing module is located above the variable diameter guiding module and is used to restrict the up-and-down movement of the hairpin wire supported on the variable diameter guiding module. The cutting module is used to control the sequential output of the hairpin wires supported on the variable diameter guiding module. The picking module is used to take out the output hairpin wires and send them to the feeding station for feeding. The actuation module 1 is used to actuate the tooling to open to receive the hairpin wires sent out by the picking module.

[0012] A preferred technical solution is as follows: The variable diameter material guiding module includes a middle rod, a left rod, a right rod, a first slide rail, a second slide rail, a connecting rod, and a diameter adjusting motor. The middle rod is inclined and fixed on the mounting frame along the feeding direction. The first slide rail and the second slide rail are fixed on the mounting frame at intervals and parallel along the diameter changing direction. The left rod is slidably mounted on the first slide rail and the second slide rail via a U-shaped bracket. The left rod is located to the left of the middle rod and is parallel to the middle rod. The right rod is slidably mounted on the first slide rail and the second slide rail via a U-shaped bracket. The right rod is located to the right of the middle rod and is parallel to the middle rod. The diameter adjusting motor is fixed on the bottom side of the mounting frame. The middle section of the connecting rod is drivenly connected to the output shaft of the diameter adjusting motor. One end of the connecting rod is rotatably connected to the bottom side of the first U-shaped bracket, and the other end of the connecting rod is rotatably connected to the bottom side of the second U-shaped bracket.

[0013] The preferred technical solution is as follows: the pressing module includes a pressing cylinder and a pressing plate. The pressing cylinder is fixed to the mounting frame via an n-type bracket. The pressing plate is located above the variable diameter guiding module and is driven by the pressing cylinder to approach or move away from the variable diameter guiding module. The picking module includes a lifting cylinder, a transfer cylinder, a gripper cylinder, and a gripper. The lifting cylinder is fixed to the side of the mounting frame and is used to drive the transfer cylinder to lift. The transfer cylinder is used to drive the gripper cylinder to move between the variable diameter guiding module and the conveying mechanism. The gripper cylinder is used to drive the gripper to clamp or release the hairpin wire. The actuation module includes an actuation cylinder and an actuation block. The actuation cylinder is mounted above the conveying mechanism and is used to drive the actuation block to approach or move away from the end of the actuation rod.

[0014] A preferred technical solution is as follows: the cutting module includes a cutting cylinder, a cutting rod, a cutting seat, a cutting block, and a spring. The cutting seat is fixed to the discharge end of the variable diameter guiding module. The discharge end of the cutting seat is provided with a downwardly inclined sliding rod, the end of which is provided with a hook. The discharge end of the cutting seat is also provided with an installation groove extending into the interior. The cutting block slides in the installation groove and at least partially extends out of the discharge end of the cutting seat. The spring is disposed in the installation groove. One end of the cutting rod abuts against the bottom of the mounting groove, and the other end abuts against the cutting block. The cutting cylinder is fixed to the mounting frame by an n-shaped bracket. The actuating end of the cutting rod is configured as an inverted L-shaped structure and has a wire-blocking part and a wire-pressing part. The wire-blocking part and the end of the cutting seat are spaced apart to form a slot for accommodating a hairpin wire. The wire-pressing part is corresponding to the part of the cutting block that extends out of the cutting seat. The cutting cylinder is used to drive the cutting rod to move along the depth direction of the slot.

[0015] The preferred technical solution is as follows: the cross-layer forming mechanism includes a support platform, a bidirectional lead screw 1, a bidirectional lead screw 2, a module 1, a module 2, a module 3, a module 4, a guide rail assembly 1, a guide rail assembly 2, a drive motor 1, and a drive motor 2. The support platform is erected above the conveying mechanism. The bidirectional lead screw 1 and the bidirectional lead screw 2 are sequentially mounted on the bottom side of the support platform in a direction perpendicular to the conveying direction of the conveying mechanism. The guide rail assembly 1 and the guide rail assembly 2 are fixed to the bottom side of the support platform and arranged parallel to the lead screw 1 and the lead screw 2. The module 1 and the guide rail assembly 2 are mounted on the bottom side of the support platform. Module 2 is slidably mounted on guide rail assembly 1 and fixedly connected to the lead screw nut screwed onto the bidirectional lead screw 1. Modules 3 and 4 are slidably mounted on guide rail assembly 2 and fixedly connected to the lead screw nut screwed onto the bidirectional lead screw 2. Drive motor 1 and drive motor 2 are both fixedly mounted on the support platform. Drive motor 1 is used to drive the bidirectional lead screw 1 to rotate, and drive motor 2 is used to drive the bidirectional lead screw 2 to rotate. Modules 1 and 2 constitute an elevation angle forming mold, and modules 3 and 4 constitute an S-bend forming mold.

[0016] The preferred technical solution is as follows: the splitting forming mechanism includes a support base, an electric slide table one, an electric slide table two, an electric slide table three, a turntable cylinder, a splitting gripper cylinder one, a splitting gripper cylinder two, a gripper assembly one, and a gripper assembly two. The electric slide table one is mounted above the conveying mechanism via the support base and is used to drive the electric slide table two to move along the X-axis. The electric slide table two is used to drive the electric slide table three to move along the Y-axis. The electric slide table three is used to drive the turntable cylinder to move along the Z-axis. The turntable cylinder is used to drive the splitting gripper cylinder one to rotate. The splitting gripper cylinder one is used to drive the gripper assembly one to clamp or release one leg of the hairpin wire. The splitting gripper cylinder two is fixed on the support base and is used to drive the gripper assembly two to clamp or release the other leg of the hairpin wire.

[0017] The preferred technical solution is as follows: the feeding mechanism includes an actuation module two, a receiving module, a pushing module, and a collecting module. The actuation module two includes an actuation cylinder two and an actuation block two. The actuation cylinder two is mounted above the conveying mechanism and is used to drive the actuation block two to approach or move away from the end of the actuation rod. The receiving module includes a receiving cylinder and a receiving rod. The receiving cylinder is mounted above the conveying mechanism and is used to drive the receiving rod to insert between the two legs of the hairpin line. The pushing module... The material module includes a pushing cylinder and a pushing rod. The pushing cylinder is mounted above the conveying mechanism and is used to drive the pushing rod to push the hairpin wire supported on the pushing rod to the collection module. The collection module includes a receiving slide, a blocking cylinder, and a blocking rod. The receiving slide is inclined on the opposite side of the receiving rod. The blocking cylinder is fixed to the lower end of the receiving slide and is used to drive the blocking rod to move up and down to block or release the hairpin wire supported on the receiving slide.

[0018] A hairpin 3D forming method based on the above-mentioned hairpin 3D forming equipment includes the following steps:

[0019] Step 1: Feed the hair clip line into the feeding mechanism;

[0020] Step 2: The feeding mechanism delivers the card-splitting line to the feeding station, where it is clamped and fixed by the tooling corresponding to the feeding station;

[0021] Step 3: The conveying mechanism first sends the tooling to the cross-layer forming station, and the cross-layer forming mechanism performs step-by-step forming of the hairpin line with elevation angle and S-bend.

[0022] Step 4: The conveying mechanism then sends the tooling to the splitting and forming station, where the splitting and forming mechanism performs splitting and forming processing on the hairpin wire;

[0023] Step 5: The conveying mechanism then sends the tooling to the unloading station, and the unloading mechanism removes the hairpin wire.

[0024] Due to the application of the above technical solution, the beneficial effects of this invention are as follows:

[0025] Solving the problems of high cost and poor flexibility: This equipment uses modular molds (modules one to four) and a two-way lead screw adjustment structure in the cross-layer forming mechanism. There is no need to replace the special molds. The mold spacing can be adjusted by simply driving the motor to adapt to hairpin lines with different elevation angles and S-bend sizes. The splitting forming mechanism achieves different top curvature forming through multi-axis linkage trajectory control, which greatly reduces the number of molds, reduces the cost of mold purchase and repair, and only requires parameter adjustment for mold change. It is time-saving, efficient and improves production flexibility.

[0026] To address the issue of easy damage to the insulation layer, a step-by-step flexible forming process of "angle forming → S-bend forming → top arc forming" is adopted to replace the traditional one-time stamping and extrusion. Each forming step is achieved through flexible clamping of the mold or control of the gripper trajectory, avoiding hard impact and scratches, effectively protecting the insulating varnish on the copper wire surface, and improving the product quality pass rate.

[0027] Enhanced versatility and automation: The variable diameter guide module of the feeding mechanism can be adapted to hairpin lines with different leg spacings without adjusting the overall structure; the conveying mechanism adopts a magnetic levitation conveyor chain, which, together with the tooling, realizes the fully automated flow of feeding, forming and unloading, reducing manual intervention and improving production efficiency; the modular design of each mechanism facilitates maintenance and upgrades. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the hair clip structure involved in the present invention.

[0029] Figure 2 This is a schematic diagram of the overall structure of the hairpin 3D molding equipment involved in this invention.

[0030] Figure 3 This is a top view of the conveying mechanism involved in the present invention.

[0031] Figure 4 for Figure 3 Enlarged diagram of point A in the middle.

[0032] Figure 5 This is a schematic diagram of the feeding mechanism involved in the present invention.

[0033] Figure 6 This is a front view of the feeding mechanism involved in the present invention.

[0034] Figure 7 This is a schematic diagram of the cross-layer forming mechanism involved in the present invention.

[0035] Figure 8 This is a schematic diagram of the splitting forming mechanism involved in the present invention.

[0036] Figure 9 This is a schematic diagram of the feeding mechanism involved in the present invention. Detailed Implementation

[0037] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification.

[0038] Please see Figures 1-9It should be noted that in the description of this invention, the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the hairpin cord of this invention is in use. These terms are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance. The terms "horizontal," "vertical," and "suspended," etc., do not indicate that the component must be absolutely horizontal or suspended, but can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0039] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0040] Example:

[0041] like Figure 1 The diagram shown is a schematic of the hairpin wire structure involved in this invention. The hairpin wire includes an upward angle portion 100, an S-curve portion 200, and a splitting portion 200.

[0042] like Figure 2 As shown, according to an overall technical concept of the present invention, a hairpin 3D forming device is provided, including a conveying mechanism 1, a feeding mechanism 2, a cross-layer forming mechanism 3, a splitting forming mechanism 4, and a discharging mechanism 5. Flexible forming is achieved through modular design. The composition, connection relationship, and operating principle of each mechanism are as follows:

[0043] like Figure 3 As shown, the conveying mechanism 1 includes a circular track 11, a magnetic levitation slider 12, and a tooling 13; wherein the tooling 13 is composed of a platform 131, a slider 132, a first hook 133, a second hook 134, a first connecting rod (not shown), a second connecting rod (not shown), a return spring 135, an actuating rod 136, and a limiting plate 137.

[0044] The circular track 11 is fixed to the frame by bolts, forming a closed loop structure, which provides a motion trajectory for the magnetic levitation slider 12; the magnetic levitation slider 12 is detachably fixed to the tooling 13 by bolts, and is slidably embedded in the circular track 11, and can slide smoothly along the track;

[0045] A rectangular assembly cavity is formed inside the stage 131. The slider 132 is slidably installed in the assembly cavity without hard friction with the cavity wall. The actuating rod 136 is arranged along the sliding direction of the slider 132. One end is fixedly connected to the end face of the slider 132 by welding, and the other end passes through the side wall of the stage 131 and extends out of the assembly cavity. The extended end is provided with a wear-resistant contact head. The return spring 135 is coaxially arranged inside the assembly cavity. One end abuts against the end face of the slider 132 away from the actuating rod 136, and the other end abuts against the inner wall of the assembly cavity. In its natural state, it pushes the slider 132. In the initial position; hook 133 and hook 2134 are symmetrical in structure and are rotatably installed in the assembly cavity via a rotating shaft. The rotating shaft is connected to the inner wall of the platform 131 via a bearing to ensure smooth rotation; connecting rod 1 and connecting rod 2 have the same structure. One end is hinged to the top of the slider 132 via a pin, and the other end is hinged to the tail end of hook 133 and hook 2134 respectively, forming a crank-connecting rod mechanism; the limiting plate 137 is fixed to one side of the platform 131 by bolts, corresponding to the hook clamping area, and a rubber buffer layer is provided on the inner side of the plate.

[0046] The magnetically levitated slider 12 is driven by electromagnetic force to move cyclically along the circular track 11, causing the tooling 13 to move precisely between each station. When the actuator rod 136 is subjected to external force, it causes the slider 132 to slide along the assembly cavity and compress the return spring 135. Through the connecting rod one and connecting rod two, the hooks 133 and 134 are pulled to rotate around the axis, causing the front ends of the two hooks to open and form a clamping opening. After the external force disappears, the return spring 135 releases its elastic potential energy, pushing the slider 132 back to its original position, causing the hooks 133 and 134 to close, thus achieving flexible clamping of one leg of the hairpin. The limiting plate 137 restricts the swing range of the other leg of the hairpin, preventing the leg from shifting during the molding process. At the same time, the rubber buffer layer reduces hard contact with the hairpin.

[0047] like Figures 5 to 6 As shown, the feeding mechanism 2 includes a mounting frame 21 and a variable diameter guiding module 22, a pressing module 23, a cutting module 24, a picking module 25 and an actuation module 26 mounted thereon.

[0048] Mounting frame 21 is made of aluminum alloy profiles and is fixed to one side of the frame with anchor bolts, corresponding to the loading station of conveying mechanism 1;

[0049] like Figures 5 to 6As shown, the variable diameter guiding module 22 has the following configuration: the middle rod 221 is inclined and fixed in the middle of the mounting frame 21 at an angle of 30°-45° (to accommodate the self-weight of the hairpin wire during feeding); slide rail 1 222 and slide rail 223 are arranged parallel and spaced apart along the variable diameter direction (perpendicular to the feeding direction) and are fixed to the platform of the mounting frame 21 by bolts; the left rod 224 is slidably embedded in the slider of slide rail 1 222 and slide rail 223 through U-shaped bracket 1, and the right rod 225 is slidably embedded in the same set of slide rails through U-shaped bracket 2, with the left rod 224 and the right rod 225 located on both sides of the middle rod 221 and kept parallel; the diameter adjusting motor 226 is fixed to the bottom side of the mounting frame 21 through the motor base, the middle section of the connecting rod 227 is connected to the output shaft of the diameter adjusting motor 226, and the two ends of the connecting rod 227 are rotatably connected to the bottom sides of U-shaped bracket 1 and U-shaped bracket 2 respectively;

[0050] Variable diameter adjustment: When the diameter adjustment motor 226 rotates forward or reverse, it drives the connecting rod 227 to swing around the output shaft. Through the U-shaped brackets one and two, it drives the left rod 224 and the right rod 225 to move closer to or further away from the middle rod 221 along the slide rail, accurately adjusting the distance between the two side rods and the middle rod 221 to adapt to hairpin lines with different leg spacing.

[0051] like Figures 5 to 6 As shown, the pressing module 23: the pressing cylinder 231 is fixed to the top of the mounting bracket 21 by an n-type bracket with a bolt, and the pressing plate 232 is connected to the piston rod of the pressing cylinder 231 by a floating joint. It is located directly above the variable diameter guiding module 22, and a silicone pressing strip is provided at the bottom of the plate.

[0052] Pressing and positioning: Pressing cylinder 231 drives pressing plate 232 to descend, and silicone pressure strip lightly presses on the surface of hairpin wire on variable diameter guide module 22 to restrict its up and down movement without damaging the insulating varnish.

[0053] like Figures 5 to 6 As shown, the cutting module 24 includes a cutting seat 241 fixed to the discharge end of the intermediate rod 221. The discharge end of the cutting seat 241 has a downwardly oriented sliding rod 2411 with a hook at its end. The discharge end of the cutting seat 241 also has an internal mounting groove. The main body of the cutting block 242 is confined within the mounting groove and slidably connected to it. A portion of the cutting block 242 extends out of the discharge end of the cutting seat 241. A spring (not shown) is located in the mounting groove, with one end of the spring... The cutting rod 244 abuts against the bottom of the mounting groove, and the other end abuts against the cutting block 242; the cutting cylinder 243 is fixed on the mounting frame 21 by an n-shaped bracket; the actuating end of the cutting rod 244 is configured as an inverted L-shaped structure and has a wire-blocking part and a wire-pressing part; the wire-blocking part and the end of the cutting seat 241 are spaced apart to form a slot for accommodating a hairpin wire; the wire-pressing part is correspondingly arranged with the part of the cutting block 242 that extends out of the cutting seat 241; the cutting cylinder 243 is used to drive the cutting rod 244 to move along the depth direction of the slot.

[0054] It should be noted that the n-type bracket two is equipped with a guide rail 245 arranged along the feeding direction, and a slide block 246 is provided on the guide rail 245. The cutting cylinder 243 is fixed on the slide block 246. The n-type bracket two is provided with a rectangular opening that limits the range of motion of the cutting cylinder 243. The main body of the cutting cylinder 243 is located in the rectangular opening, and an elastic element 247 is also provided in the rectangular opening. The elastic element 247 is arranged along the sliding direction of the slide block 246, with one end abutting against the cylinder body of the cutting cylinder 243, and the other end abutting against the inner wall of the rectangular opening near the discharge side. This structure can adaptively adjust the groove width of the card slot based on the thickness of the card wire to meet the feeding of different specifications of card wire.

[0055] Material cutting and discharge: The hairpin wire is guided by the intermediate rod 221 to slide into the slot. The cutting cylinder 243 drives the cutting rod 244 to move along the depth of the slot. The wire pressing part presses the hairpin wire to abut against the cutting block 242 and compress the spring, causing a single hairpin wire to slide down the slide rod 2411 at the discharge end of the cutting seat 241. The hook at the end of the slide rod 2411 temporarily supports the hairpin wire, waiting for material to be picked up. After the spring returns to its original position, the cutting block 242 is pushed out, the cutting cylinder 243 returns to its original position and re-forms the slot, and the hairpin wire on the rear side slides into the slot, and the cycle continues.

[0056] like Figures 5 to 6 As shown, the material handling module 25: the lifting cylinder 251 is vertically fixed to the side of the mounting frame 21 by a bracket, the transfer cylinder 252 is fixed to the top of the piston rod of the lifting cylinder 241 by a connecting plate, the gripper cylinder 253 is installed on the slider of the transfer cylinder 252, and the gripper 254 is installed on the output end of the gripper cylinder 253 by bolts.

[0057] Material handling and transfer: Lifting cylinder 251 drives transfer cylinder 252 to descend, gripper cylinder 253 drives gripper 254 to close and clamp the carding line, then lifting cylinder 251 resets and transfer cylinder 252 pushes horizontally to transfer the carding line to the loading station.

[0058] like Figure 4 As shown, the actuation module 26: the actuation cylinder 261 is mounted and fixed above the loading station of the conveying mechanism 1 by a gantry frame, and the actuation block 262 is fixed to the end of the piston rod of the actuation cylinder 261, corresponding to the extended end of the actuation rod 136 of the tooling 13;

[0059] Tooling docking: Actuating cylinder 261 drives actuating block 262 to extend, presses actuating rod 136 of tooling 13, causes the hook to open, the gripper to release the hairpin line, and causes one leg to enter the clamping area. Then actuating cylinder 261 resets, the hook closes to clamp, and the loading is completed.

[0060] like Figure 7As shown, the cross-layer forming mechanism 3 includes a support platform 31, a bidirectional lead screw 1 32, a bidirectional lead screw 2 33, a module 1 34, a module 2 35, a module 3 36, a module 4 37, a guide rail assembly 1 38, a guide rail assembly 2 39, a drive motor 1 310, and a drive motor 2 311.

[0061] The support platform 31 is fixed to the frame by four column bolts and is erected directly above the cross-layer forming station of the conveying mechanism 1. Two bidirectional lead screws 32 and 33 are arranged parallel to each other along a direction perpendicular to the conveying direction, with both ends rotatably mounted on the bottom side of the support platform 31 via bearing seats. The lead screw surfaces are provided with left- and right-hand threads. Guide rail assemblies 38 and 39 correspond one-to-one with two bidirectional lead screws 32 and 33, and are fixed to the bottom side of the support platform 31 by bolts, parallel to the corresponding lead screws. Modules 34 and 35 are fixed to the left- and right-hand thread nuts of the bidirectional lead screw 32 by bolts, and are simultaneously slidably embedded in guide rail assembly 38. On the slide rail of 8; Module 36 and Module 437 are fixed to the left and right turning screw nuts of the double-acting screw 23 by bolts and are slidably embedded on the slide rail of the guide rail assembly 239; Drive motor 1310 and Drive motor 2311 are fixed to the support platform 31 by motor bases, and the output shafts are connected to one end of the double-acting screw 132 and the double-acting screw 23 by couplings; The end faces of Module 134 and Module 235 opposite to each other are provided with arc-shaped forming grooves to form an upward angle forming mold; The end faces of Module 36 and Module 437 opposite to each other are provided with S-shaped forming grooves to form an S-bend forming mold, and the inner walls of the forming grooves are all provided with polytetrafluoroethylene wear-resistant layers.

[0062] Upward Angle Forming: Drive motor 310 starts, driving the bidirectional lead screw 32 to rotate via the coupling. The left and right turns of the lead screw nut drive modules 34 and 35 to move synchronously relative to each other along guide rail assembly 38, wrapping the corresponding part of the hair clip wire within the arc-shaped forming groove. By precisely controlling the distance and movement speed of the two modules, the preset angle of upward forming is achieved. S-Bend Forming: After the upward angle forming is completed, drive motor 311 starts, driving the bidirectional lead screw 33 to rotate. Modules 36 and 37 move relative to each other along guide rail assembly 39, progressively bending another part of the hair clip wire through the S-shaped forming groove to form the required S-bend structure. The step-by-step forming design avoids damage to the insulation layer caused by one-time extrusion, and can be adapted to different sizes of upward angles and S-bend requirements by adjusting the motor parameters, without the need to change the mold.

[0063] like Figure 8 As shown, the splitting forming mechanism 4 includes a support base 41, an electric slide table 42, an electric slide table 43, an electric slide table 44, a turntable cylinder 45, a splitting gripper cylinder 46, a splitting gripper cylinder 47, a gripper assembly 48, and a gripper assembly 49.

[0064] Support base 41 is bolted to the frame and located above the splitting forming station of conveying mechanism 1, forming a gantry structure; electric slide table one 42 is horizontally fixed to the crossbeam of support base 41, and its sliding direction is the X-axis; electric slide table two 43 is vertically fixed to the sliding seat of electric slide table one 42, and its sliding direction is the Y-axis; electric slide table three 44 is vertically fixed to the sliding seat of electric slide table two 43, and its sliding direction is the Z-axis; turntable cylinder 45 is fixed to the sliding seat of electric slide table three 44 through a flange, and its output shaft can rotate 360°; splitting gripper cylinder one 46 is bolted to the output end of turntable cylinder 45, and gripper assembly one 48 is installed at its output port, with a flexible rubber pad on the inner side of the gripper; splitting gripper cylinder two 47 is fixed to support base 41 and is arranged opposite to gripper assembly one 48, and gripper assembly two 49 is installed at its output port, with the same structure as gripper assembly one 48.

[0065] Positioning and clamping: The second splitting gripper cylinder 47 first drives the second gripper assembly 49 to close, clamping the fixed leg of the hair clip and ensuring that the leg remains stationary during the forming process; the first splitting gripper cylinder 46 drives the first gripper assembly 48 to close, clamping the movable leg of the hair clip; Multi-axis linkage forming: the electric slide table 42 (X-axis), the second electric slide table 43 (Y-axis), and the third electric slide table 44 (Z-axis) move in coordination according to a preset trajectory. At the same time, the turntable cylinder 45 drives the first splitting gripper cylinder 46 to rotate, so that the first gripper assembly 48 drives the movable leg to move along a three-dimensional trajectory to achieve the arc forming of the top of the hair clip; during the forming process, the gripper assembly maintains a flexible clamping force to avoid damaging the insulating varnish and ensure the accuracy of the top arc dimension.

[0066] like Figure 9 As shown, the feeding mechanism 5 includes an actuation module 51, a receiving module 52, a pushing module 53, and a collecting module 54.

[0067] Actuation Module 2 51: Actuation cylinder 2 511 is fixed above the unloading station of conveying mechanism 1 via a gantry frame, and actuation block 2 512 is fixed to the end of its piston rod, corresponding to the end of actuation rod 136 of tooling 13, with the same structure as actuation module 1 26; Receiving Module 52: Receiving cylinder 521 is fixed above the unloading station via a bracket, and receiving rod 522 is fixed to the end of its piston rod; Pushing Module 53: Pushing cylinder 531 is fixed above the unloading station via a bracket. The push rod 532 is fixed to the end of its piston rod, and the front end of the rod is provided with a nylon push head; the collection module 54: the receiving slide rod 541 is fixed to the side of the frame by a bracket, and is set opposite to the receiving rod 522, with an inclination angle of 20°-30°, so as to facilitate the sliding of the hairpin line; the blocking cylinder 542 is fixed to the low end bracket of the receiving slide rod 541 by bolts, and the blocking rod 543 is fixed to the top of the piston rod of the blocking cylinder 542, and is vertically set below the receiving slide rod 541.

[0068] Receiving: Receiving cylinder 521 drives receiving rod 522 to extend, and receiving rod 522 is inserted between the two legs of the hairpin wire; Releasing hairpin wire: Actuating cylinder 2 511 drives actuating block 2 512 to extend, pressing the actuating rod 136 of tooling 13, causing hook 1 133 and hook 2 134 to open, releasing the formed hairpin wire; Pushing: Pushing cylinder 531 drives pushing rod 532 to extend, pushing it from receiving rod 522 to receiving slide bar 541; Collecting: The hairpin wire slides down the inclined receiving slide bar 541, and the blocking cylinder 542 drives the blocking rod 543 to rise, preventing the hairpin wire from falling and achieving temporary storage; When the hairpin wire on the receiving slide bar 541 accumulates to a preset number, the blocking cylinder 542 drives the blocking rod 543 to descend, and the hairpin wire falls into the collection box in batches, completing the unloading.

[0069] Complete process of hair clip 3D molding

[0070] Step 1: Material preparation

[0071] The hair clips to be formed are fed in batches into the variable diameter guiding module 22 of the feeding mechanism 2. The diameter adjusting motor 226 automatically adjusts the distance between the left rod 224, the right rod 225 and the middle rod 221 according to the support leg distance of the hair clips in this batch, so as to ensure that the hair clips are stably supported. The pressing module 23 is started, and the pressing plate 232 descends to limit its up and down movement.

[0072] Step 2: Fixture clamping and positioning

[0073] The cutting module 24 controls the output of the carding wires sequentially along the slide bar 2411 according to the principle of "single wire output";

[0074] The lifting cylinder 251 and the transfer cylinder 252 of the material handling module 25 work together to grip a single hairpin wire and transfer it to the loading station.

[0075] Actuation module 1 26 drives actuation block 262 to press actuation rod 136, tooling 13 opens the hook claw, one leg of the hairpin line enters the clamping area, actuation module 1 26 resets, the hook claw closes to clamp, and the other leg is limited by limit plate 137 to complete positioning.

[0076] Step 3: Cross-layer molding process

[0077] The magnetic levitation slider 12 of the conveyor mechanism 1 drives the tooling 13 and the hairpin line to the cross-layer forming station, and after positioning:

[0078] When drive motor 310 starts, modules 34 and 35 move relative to each other to complete the hairpin line elevation angle forming;

[0079] When drive motor 2 (311) starts, modules 3 (36) and 4 (37) move relative to each other to complete the S-bend forming of the hairpin line;

[0080] After forming, each module moves in reverse to reset and release the hairpin wire.

[0081] Step 4: Splitting and shaping process

[0082] The magnetic levitation slider 12 drives the tooling 13 to the splitting forming station, and after positioning:

[0083] The splitting gripper cylinder 247 drives the gripper assembly 249 to hold the hairpin wire and fix the support leg;

[0084] Splitting gripper cylinder 46 drives gripper assembly 48 to hold movable support leg;

[0085] Electric slide table 1 42, electric slide table 2 43, electric slide table 3 44 and turntable cylinder 45 move in tandem according to a preset trajectory to complete the top arc forming of the hairpin line;

[0086] After molding, the two gripper assemblies open and reset.

[0087] Step 5: Material collection

[0088] The magnetic levitation slider 12 drives the tooling 13 to the unloading station, and after positioning:

[0089] The receiving module 52 inserts the receiving rod 522 between the two legs of the hairpin wire;

[0090] Actuator module 2 51 drives actuator block 2 511 to press actuator rod 136, and the hook opens to release the hairpin line;

[0091] The pusher module 53 pushes the card-sending wire from the receiving rod 522 to the receiving slide bar 541;

[0092] The stop bar 543 rises to block the hairpin wires. After accumulating to a preset quantity, the stop bar 543 descends, the hairpin wires are collected in batches, and the tooling 13 returns to the loading station with the magnetic levitation slider 12 to enter the next cycle.

[0093] This equipment does not require special stamping dies, reducing production costs and improving changeover flexibility. It also avoids damage to the insulating varnish and has the advantages of high automation and strong versatility. It effectively solves the technical problems of high cost, poor flexibility and easy damage to insulation in traditional die stamping. It is suitable for 3D forming of flat wire motor hairpin wire.

[0094] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. A hairpin wire 3D forming apparatus characterized by: The device comprises a conveying mechanism, a feeding mechanism, a cross-layer forming mechanism, a splitting and drawing forming mechanism and a discharging mechanism, the conveying mechanism is used for controlling the circulation of the jig for clamping the hairpin wire between the feeding station, the cross-layer forming station, the splitting and drawing forming station and the discharging station; the feeding mechanism is correspondingly arranged with the feeding station and is used for sending the hairpin wire to the conveying mechanism; the cross-layer forming mechanism is correspondingly arranged with the cross-layer forming station and is used for performing the step-by-step forming treatment of the hairpin wire in the elevation angle and S-bend; the splitting and drawing forming mechanism is correspondingly arranged with the splitting and drawing forming station and is used for performing the splitting and drawing forming treatment on the hairpin wire; and the discharging mechanism is correspondingly arranged with the discharging station and is used for taking out the hairpin wire from the conveying mechanism.

2. The hairpin wire 3D forming apparatus according to claim 1, characterized by: The conveying mechanism adopts a magnetic suspension conveying chain, comprising a ring track and magnetic suspension sliders slidingly installed on the ring track, and each of the magnetic suspension sliders is provided with the jig; the jig comprises a carrier, a slider, a hook claw one, a hook claw two, a connecting rod one, a connecting rod two, a return spring, an actuating rod and a limiting plate, the carrier is provided with an assembly cavity, the slider is slidingly arranged in the assembly cavity, the actuating rod is arranged along the sliding direction of the slider and is fixedly connected with the slider at one end and extends out of the assembly cavity at the other end; the return spring is arranged in the assembly cavity along the sliding direction of the slider, one end of the spring is abutted against the slider, and the other end is abutted against the assembly cavity; the hook claw one and the hook claw two are the same in structure and are both arranged in the assembly cavity, one end of the connecting rod one is hingedly connected with the slider, and the other end is hingedly connected with the tail end of the hook claw one, one end of the connecting rod two is hingedly connected with the slider, and the other end is hingedly connected with the tail end of the hook claw two, the hook claw one and the hook claw two are oppositely arranged to form a clamping structure for clamping or releasing one leg of the hairpin wire; and the limiting plate is fixedly arranged on the carrier and is used for limiting the swing range of the other leg of the hairpin wire.

3. The hairpin wire 3D forming apparatus according to claim 2, characterized by: The feeding mechanism comprises a mounting frame, a variable-diameter material guiding module, a material pressing module, a material cutting module, a material taking module and an actuating module one arranged on the mounting frame, the variable-diameter material guiding module realizes variable-diameter support and material guiding based on the distance between the two legs of the hairpin wire, the material pressing module is arranged above the variable-diameter material guiding module and is used for limiting the up-and-down movement of the hairpin wire supported on the variable-diameter material guiding module, the material cutting module is used for controlling the hairpin wire supported on the variable-diameter material guiding module to be sequentially discharged, the material taking module is used for taking out the discharged hairpin wire and feeding it to the feeding station for feeding, and the actuating module one is used for actuating the jig to be opened to receive the hairpin wire fed out by the material taking module.

4. The hairpin wire 3D forming apparatus according to claim 3, characterized by: The variable-diameter material guiding module comprises an intermediate rod, a left rod, a right rod, a sliding rail one, a sliding rail two, a connecting rod and a diameter adjusting motor, the intermediate rod is fixedly arranged on the mounting frame and inclined along the material feeding direction, the sliding rail one and the sliding rail two are fixedly arranged on the mounting frame and parallel along the variable-diameter direction, the left rod is slidably arranged on the sliding rail one and the sliding rail two through a u-shaped bracket one, the left rod is arranged on the left side of the intermediate rod and parallel to the intermediate rod, the right rod is slidably arranged on the sliding rail one and the sliding rail two through a u-shaped bracket two, the right rod is arranged on the right side of the intermediate rod and parallel to the intermediate rod; the diameter adjusting motor is fixedly arranged on the bottom side of the mounting frame, the middle section of the connecting rod is in transmission connection with the output shaft of the diameter adjusting motor, one end of the connecting rod is in rotational connection with the bottom side of the u-shaped bracket one, and the other end of the connecting rod is in rotational connection with the bottom side of the u-shaped bracket two.

5. The hairpin wire 3D forming apparatus according to claim 3, characterized by: The material pressing module comprises a material pressing cylinder and a material pressing plate, the material pressing cylinder is fixedly arranged on the mounting frame through an n-shaped bracket one, and the material pressing plate is arranged above the variable-diameter material guiding module and is driven by the material pressing cylinder to approach or move away from the variable-diameter material guiding module; the material taking module comprises a lifting cylinder, a moving cylinder, a clamping jaw cylinder and a clamping jaw, the lifting cylinder is fixedly arranged on the side of the mounting frame and is used to drive the moving cylinder to lift, the moving cylinder is used to drive the clamping jaw cylinder to move between the variable-diameter material guiding module and the conveying mechanism, and the clamping jaw cylinder is used to drive the clamping jaw to clamp or release the hairpin wire; the actuating module one comprises an actuating cylinder one and an actuating block, the actuating cylinder one is arranged above the conveying mechanism and is used to drive the actuating block to approach or move away from the end of the actuating rod.

6. The hairpin wire 3D forming apparatus according to claim 3, characterized by: The material cutting module comprises a material cutting cylinder, a material cutting rod, a material cutting seat, a material cutting block and a spring, the material cutting seat is fixedly arranged on the discharging end of the variable-diameter material guiding module, the discharging end of the material cutting seat is provided with a sliding rod which is arranged inclined downward, the end of the sliding rod is provided with a hook, the discharging end of the material cutting seat is also provided with a mounting groove which extends to the inside, the material cutting block is slidably arranged in the mounting groove and at least partially extends out of the discharging end of the material cutting seat, the spring is arranged in the mounting groove, one end of the spring abuts against the bottom of the mounting groove, and the other end of the spring abuts against the material cutting block; the material cutting cylinder is fixedly arranged on the mounting frame through an n-shaped bracket two, the actuating end of the material cutting rod is in the shape of inverted L and has a wire blocking portion and a wire pressing portion, the wire blocking portion and the end of the material cutting seat are arranged in parallel to form a clamping groove for accommodating one hairpin wire, the wire pressing portion is correspondingly arranged with the part of the material cutting block which extends out of the material cutting seat, and the material cutting cylinder is used to drive the material cutting rod to move along the depth direction of the clamping groove.

7. The hairpin wire 3D forming apparatus according to claim 1, characterized by: The cross-layer forming mechanism comprises a support platform, a bidirectional screw rod one, a bidirectional screw rod two, a module one, a module two, a module three, a module four, a guide rail assembly one, a guide rail assembly two, a driving motor one and a driving motor two, the support platform is arranged above the conveying mechanism, the bidirectional screw rod one and the bidirectional screw rod two are sequentially arranged on the bottom side of the support platform in a direction perpendicular to the conveying direction of the conveying mechanism, the guide rail assembly one and the guide rail assembly two are fixedly arranged on the bottom side of the support platform and are arranged in parallel with the screw rod one and the screw rod two, the module one and the module two are slidably arranged on the guide rail assembly one and are fixedly connected with the screw nut arranged on the bidirectional screw rod one, the module three and the module four are slidably arranged on the guide rail assembly two and are fixedly connected with the screw nut arranged on the bidirectional screw rod two, the driving motor one and the driving motor two are fixedly arranged on the support platform, the driving motor one is used for driving the bidirectional screw rod one to rotate, and the driving motor two is used for driving the bidirectional screw rod two to rotate; the module one and the module two constitute an elevation angle forming die, and the module three and the module four constitute an S-bend forming die.

8. The hairpin wire 3D forming apparatus according to claim 1, characterized by: The cleaving forming mechanism comprises a support base, an electric sliding table one, an electric sliding table two, an electric sliding table three, a rotary table cylinder, a cleaving clamp jaw cylinder one, a cleaving clamp jaw cylinder two, a clamp jaw assembly one and a clamp jaw assembly two, the electric sliding table one is arranged above the conveying mechanism through the support base and is used for driving the electric sliding table two to move along the X-axis direction, the electric sliding table two is used for driving the electric sliding table three to move along the Y-axis direction, the electric sliding table three is used for driving the rotary table cylinder to move along the Z-axis direction, the rotary table cylinder is used for driving the cleaving clamp jaw cylinder one to rotate, the cleaving clamp jaw cylinder one is used for clamping or releasing one leg of the hairpin wire, and the cleaving clamp jaw cylinder two is fixedly arranged on the support base and is used for driving the clamp jaw assembly two to clamp or release the other leg of the hairpin wire.

9. The hairpin wire 3D forming apparatus according to claim 2, characterized by: The blanking mechanism comprises an actuating module two, a receiving module, a pushing module and a collecting module, the actuating module two comprises an actuating cylinder two and an actuating block two, the actuating cylinder two is arranged above the conveying mechanism and is used for driving the actuating block two to approach or move away from the end of the actuating rod; the receiving module comprises a receiving cylinder and a receiving rod, the receiving cylinder is arranged above the conveying mechanism and is used for driving the receiving rod to be inserted between the two legs of the hairpin wire; the pushing module comprises a pushing cylinder and a pushing rod, the pushing cylinder is arranged above the conveying mechanism and is used for driving the pushing rod to push the hairpin wire supported on the pushing rod to the collecting module; the collecting module comprises a receiving slide rod, a blocking cylinder and a blocking rod, the receiving slide rod is arranged on the opposite side of the receiving rod, the blocking cylinder is fixedly arranged on the low side end of the receiving slide rod and is used for driving the blocking rod to move up and down to block or release the hairpin wire supported on the receiving slide rod.

10. A hairpin 3D molding method based on the hairpin 3D molding apparatus according to any one of claims 1 to 9, characterized by, The method comprises the following steps: Step 1: feeding the hairpin wire into the feeding mechanism; Step 2: the feeding mechanism sends the hairpin wire to the feeding station, and the tool corresponding to the feeding station clamps and fixes it; Step 3: the conveying mechanism first sends the tool to the cross-layer forming station, and the cross-layer forming mechanism performs step-by-step forming processing on the hairpin wire in terms of elevation angle and S-bending; Step 4: the conveying mechanism then sends the tool to the split-drawing forming station, and the split-drawing forming mechanism performs split-drawing forming processing on the hairpin wire; Step 5: the conveying mechanism then sends the tool to the discharging station, and the discharging mechanism takes out the hairpin wire.

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