Hairpin forming apparatus for motor of electric vehicle

Abstract

A hairpin forming apparatus of a motor includes: a stopper for sensing contact of a leading end of a material coil and aligning the leading end of the material coil at a predetermined position; a cutting member for cutting the material coil aligned by the stopper into a predetermined length; a coil holder disposed between the stopper and the cutter such that the material coil is placed on the coil holder; and a pressing module for pressing and bending the material coil placed on the coil holder. The pressing module includes: a die holder fixed to the coil holder; the main pressing machine is used for pressing the material coil towards the die base so as to form the chuck piece and the clamping shoulder piece; and the side pressing machine is used for pressing the two sides of the material coil at the position deviating from the mold base and the main pressing machine so as to form the pair of clamping arm pieces.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of Korean Patent Application No. 10-2024-0130621, filed on September 26, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to a hairpin forming apparatus for an electric motor of an electric vehicle, and more particularly, to a hairpin forming apparatus configured to cut material coils to a predetermined length and bend the cut material coils by a pressing process to form a clamp, a shoulder, and a arm. Background Technology

[0004] Electric vehicles are driven by electric motors. Electric motors use electrical energy to generate kinetic energy. Most electric motors consist of a stator and a rotor. The stator is wound with highly conductive copper wire. When current flows through the wire, a magnetic field is created around the stator. The rotor is constructed with a steel core or a magnet and rotates under the influence of the magnetic field generated by the stator. The motor converts the electrical energy supplied to the stator into the rotational motion of the rotor.

[0005] As the volume density of copper wire wound on the stator increases, the efficiency and performance of the motor can be improved. For this reason, copper wire with a rectangular cross-section can be used to allow for a denser winding of the copper wire on the stator.

[0006] In addition, in order to improve the performance and efficiency of motors, a method is widely used that involves cutting copper wires to a predetermined length, transforming them into hairpin-shaped pieces, and then installing the hairpin-shaped pieces in stator slots.

[0007] The hairpin-shaped component is manufactured by processing copper wire coils with a rectangular cross-section, and the surface of the hairpin-shaped component is coated with a thin insulating film. This insulating film is mainly composed of insulating materials such as enamel.

[0008] Multiple hairpin-shaped components are installed in the stator slots to form the stator, and an insulating film is required to prevent electrical short circuits between adjacent hairpin-shaped components. To achieve electrical connection with the circuit, a portion of the insulating film coated on both ends of each hairpin-shaped component can be removed to expose the copper wire.

[0009] In traditional manufacturing methods, copper wires fed in real-time undergo sequential processes such as bending, stripping, and cutting. However, because each process requires different times, the overall production time is long, resulting in low productivity. Furthermore, the pressing and forming tools suffer from short lifespans due to repeated exposure to significant forces, and their maintenance is expensive and time-consuming. There is also the problem of frequently replacing large and heavy machining tools. Summary of the Invention

[0010] An aspect of the present disclosure relates to an electric motor for an electric vehicle, and more particularly, to solving a problem of a large shape variation of a hairpin-shaped member manufactured in a predetermined three-dimensional shape by machining a material coil in the related art.

[0011] Another aspect of the present disclosure relates to solving a problem of a bent portion of a material coil being easily cracked or an insulating film being easily damaged in the related art.

[0012] Still another aspect of the present disclosure relates to solving a problem of a short replacement period of a machining tool for machining a material coil and expensive and time-consuming replacement of the machining tool in the related art.

[0013] Aspects of the present disclosure are not limited to the above-described aspects, and other aspects or objects not mentioned herein will be clearly understood by those skilled in the art from the following description.

[0014] A hairpin-shaped member forming apparatus according to an embodiment of the present disclosure is an apparatus for forming a hairpin-shaped member of an electric motor, and includes a stopper configured to sense contact of a leading end of a material coil fed in one direction and to align the leading end of the material coil at a predetermined position, a cutting member including a cutting blade positioned at a predetermined distance from the stopper, the cutting member being configured to cut the material coil aligned by the stopper into a predetermined length, a coil holder disposed between the stopper and the cutting member, the coil holder being configured to allow the material coil to be placed on the coil holder, and a press module configured to press and bend the material coil placed on the coil holder.

[0015] According to another aspect, a hairpin-shaped member forming apparatus is a machining apparatus that manufactures a hairpin-shaped member by machining a linear material coil, and includes a stopper, a cutting member, a coil holder, and a press module. The stopper senses contact of a leading end of a material coil fed in one direction and aligns the leading end of the material coil at a predetermined position. The cutting member includes a cutting blade spaced apart from the stopper by a predetermined distance and cuts the material coil aligned by the stopper into a predetermined length. The coil holder is disposed between the stopper and the cutting member, and the material coil is placed on the coil holder. The press module presses and bends the material coil placed on the coil holder. The press module includes a die seat fixed to a front surface of the coil holder, a portion of an outer surface of the die seat having a die machining surface formed thereon, a main press configured to press the material coil toward the die seat to form a collet member and a collet shoulder member, and a side press configured to press both sides of the material coil located at a position deviated from the die seat and the main press from above to below to form a pair of collet arm members.

[0016] In the hairpin forming apparatus according to an embodiment of the disclosure, the main press includes a main lifting unit configured to rise and fall as a rotation of a cam shaft is driven, an upper press body coupled to a lower end of the main lifting unit so as to vertically rise and fall above the mold base, and a center press body disposed between the mold base and the upper press body, the center press body being configured to press the material coil forward toward the upper press body to form the clip.

[0017] Optionally, in the hairpin forming apparatus according to an embodiment of the disclosure, the upper press body includes a base block including a rear surface formed flat, a base processing surface formed on a front surface of the base block in such a manner that a height and a front-rear thickness of the base processing surface gradually decrease from a center thereof to both sides thereof, and first and second coupling portions disposed above the base processing surface, a shoulder piece block coupled to the second coupling portion, the shoulder piece block including a front surface protruding more forward than the base processing surface and an upper end formed horizontally, the shoulder piece block being formed in such a manner that a vertical length thereof gradually increases downward from a center thereof to both sides thereof, and an upper coupling knob coupled to the first coupling portion and in contact with an upper surface of the shoulder piece block, an upper end of the upper coupling knob being coupled to the main lifting unit.

[0018] In the hairpin forming apparatus according to an embodiment of the disclosure, the upper press body and the center press body of the main press can be separable from each other.

[0019] Optionally, in the hairpin forming apparatus according to an embodiment of the disclosure, the base block and the shoulder piece block of the upper press body can be individually replaceable.

[0020] In the hairpin forming apparatus according to an embodiment of the disclosure, the center press body can include a center processing surface formed in a shape corresponding to the base processing surface in a case where the center processing surface faces the base processing surface, and a center coupling knob extending through the coil holder and the mounting frame in a direction opposite to the center processing surface.

[0021] Optionally, in the hairpin forming apparatus according to an embodiment of the disclosure, the center processing surface of the center press body can move forward and backward toward the base processing surface through the mounting frame and the coil holder.

[0022] A vehicle can include an electric motor having the hairpin formed by the apparatus.

[0023] An electric vehicle can include an electric motor having the hairpin formed by the apparatus. BRIEF DESCRIPTION OF DRAWINGS

[0024] The above and other objects, features and other advantages of the present disclosure will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0025] Figure 1 is a view for illustrating a hairpin of an electric machine;

[0026] Figure 2 is a perspective view for illustrating a coil of material wound on a winding bobbin;

[0027] Figure 3 is a flowchart for illustrating a process of manufacturing a hairpin of an electric machine;

[0028] Figure 4 is a hairpin manufacturing process diagram schematically showing an overall process of manufacturing a hairpin of an electric machine;

[0029] Figure 5 is a front view schematically showing an apparatus for shaping a hairpin according to an embodiment of the present disclosure;

[0030] Figure 6 is an exploded perspective view showing an upper pressing body in an apparatus for shaping a hairpin according to an embodiment of the present disclosure;

[0031] Figure 7 is a perspective view showing an upper pressing body in an apparatus for shaping a hairpin according to an embodiment of the present disclosure;

[0032] Figure 8 is a longitudinal sectional view for illustrating a pressing module in an apparatus for shaping a hairpin according to an embodiment of the present disclosure; and

[0033] Figure 9 and Figure 10 is a view showing a process of processing a coil of linear material into a shape of a hairpin by an apparatus for shaping a hairpin according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0034] It is understood that the term “vehicle” or “vehicular” or other similar terminology as used herein, is generally inclusive of a motor vehicle, such as a passenger automobile, including sport utility vehicles (SUV), buses, trucks, passenger vehicles of various sizes, including various commercial vehicles, watercraft including various boats and ships, an aircraft, and the like, and includes a hybrid vehicle, electric vehicle, plug-in hybrid electric vehicle, hydrogen vehicle, and other alternative fuel (e.g., fuel derived from a resource other than petroleum) vehicle. As referred to herein, a hybrid vehicle is a vehicle having two or more sources of power, such as a gasoline and electric dual power vehicle.

[0035] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. Throughout this specification, the word "comprise," and variations such as "comprises" or "comprising," will be understood to imply the inclusion of a stated element, but not to the exclusion of any other elements. In addition, the terms "unit", "-er", "-piece" and "module" described in the specification mean a unit for processing at least one function and operation, and can be implemented by hardware components or software components and combinations thereof.

[0036] Further, the control logic of the present disclosure can be implemented as a non-transitory computer readable medium on a computer readable medium containing executable program instructions run by a processor, a controller, and the like. Examples of the computer readable medium include, but are not limited to, ROM, RAM, compact disc (CD)-ROM, magnetic tapes, floppy disks, flash drives, smart cards, and optical data storage devices. The computer readable medium can also be distributed over network-coupled computer systems so that the computer readable medium is stored and executed in a distributed fashion, e.g., by a remote processing server or a controller area network (CAN).

[0037] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings.

[0038] In the following description of embodiments disclosed in the specification, a detailed description of known functions and configurations incorporated herein can be omitted when it can make the subject matter of the embodiments disclosed in the specification rather unclear.

[0039] In addition, the accompanying drawings are provided only for better understanding of the embodiments disclosed in the specification, and are not intended to limit the technical idea disclosed in the specification.

[0040] It will be understood that when a component is referred to as being "connected to" or "coupled to" another component, the component can be directly connected to or coupled to the other component, or intervening components can be present.

[0041] The first direction X, the second direction Y, and the third direction Z described herein refer to respective dimensions and directions of a three-dimensional coordinate system for describing a three-dimensional shape. Accordingly, the first direction X, the second direction Y, and the third direction Z can be represented by arrows that are perpendicularly intersected with each other in space.

[0042] The present disclosure relates to an apparatus 68 for shaping hairpin-shaped pieces 10.

[0043] Figure 1 is a view for explaining a hairpin-shaped piece of a motor, and Figure 2 is a perspective view for explaining a material coil wound on a winding bobbin.

[0044] Referring to Figure 1 and Figure 2 , an electric motor includes a stator 20 and a rotor.

[0045] The stator 20 corresponds to a fixed part of the motor, and a material coil 50 is wound on a stator core 22 in a predetermined direction.

[0046] As shown, the material coil 50 can be processed into the shape of the hairpin-shaped piece 10, and can be coupled to the stator core 22. The stator core 22 can be provided in plurality, and the plurality of stator cores 22 can be provided at regular intervals. Each of the stator slots 24 is formed between adjacent stator cores among the stator cores 22.

[0047] The material coil 50 can be cut into a predetermined length (feed interval), and the cut material coil can be transformed into the hairpin-shaped piece 10. The hairpin-shaped piece 10 can be installed in each of the stator slots 24.

[0048] When a current is applied to the hairpin-shaped pieces 10 densely coupled to the stator 20, a magnetic field is formed around the stator 20. Then, the rotor rotates relative to the stator 20 under the influence of the magnetic field formed around the stator 20.

[0049] The apparatus 68 for shaping the hairpin-shaped piece 10 according to the embodiment of the present disclosure can be used in the process of manufacturing the hairpin-shaped piece 10.

[0050] The hairpin-shaped piece 10 is manufactured by processing the material coil 50 cut into a predetermined length (hereinafter referred to as "feed interval"). Alternatively, in some embodiments of the present disclosure, a bending, peeling, or grooving process can be performed on some portions of the material coil 50 in advance, and a process of cutting the material coil 50 in units of the feed interval can be performed after the processing and peeling process.

[0051] The material coil 50 is a wire-shaped conductor having a rectangular cross section.

[0052] In detail, the material coil 50 includes a conductive core 58 made of a conductive material and an insulating film 59 coated on the surface of the conductive core 58. The conductive core 58 can be a wire-shaped copper member having a rectangular cross section, and the insulating film 59 can be an insulating material, such as enamel, coated to a predetermined thickness on the surface of the conductive core 58.

[0053] The hairpin-like member 10 is manufactured by cutting the wire-like material coil 50 into a predetermined length, and a pair of conductive terminals 18 is formed at each end of the hairpin-like member 10. The pair of conductive terminals 18 is formed to have a predetermined length at each end of the hairpin-like member 10.

[0054] The conductive terminal 18 corresponds to a portion of the material coil 50 from which the insulating film 59 is removed. The conductive terminal 18 can be used as a terminal for electrical connection.

[0055] The hairpin-like member 10 can be divided into the clip head member 12, the clip shoulder members 14, the clip arm members 16, and the aforementioned conductive terminals 18.

[0056] The clip head member 12 is located at the center of the hairpin-like member 10. The clip head member 12 corresponds to a vertex portion that is bent at a predetermined angle.

[0057] The clip head member 12 is a point at which the pair of clip shoulder members 14 meet each other. The pair of clip shoulder members 14 are linear portions that extend to both sides from the clip head member 12.

[0058] Based on a state in which the sharply bent portion of the clip head member 12 is oriented upward as shown in FIG. 1A, in a plan view and a front view, the pair of clip shoulder members 14 can correspond to between the angles of a virtual triangle and the vertexes of the angles are two sides of the clip head member 12. Figure 1

[0059] The clip arm members 16 extend downward from the end portions of the respective clip shoulder members 14. The clip arm members 16 are formed as linear portions that extend straight in the up-down direction, and the conductive terminals 18 are provided at the lower ends of the respective clip arm members 16. In addition, the two clip arm members 16 can be provided in parallel to each other.

[0060] The material coil 50 used to manufacture the hairpin-like member 10 is a linear member having a rectangular cross section, and is generally stored and transported in a state of being wound on a winding bobbin 40.

[0061] The winding bobbin 40 can include a bobbin core 44 having a cylindrical shape, a shield plate mounted on each end of the bobbin core 44, and a center hole 42 that is a through-hole formed through the center of the bobbin core 44 in the longitudinal direction of the bobbin core 44.

[0062] The material coil 50 having a rectangular cross section includes a long side portion 52 having a relatively long length and a short side portion 54 having a relatively short length.

[0063] The pair of clip shoulder members 14 are portions that extend straight to both sides from the clip head member 12, and the pair of clip arm members 16 are linear portions that are bent downward and extend from the end portions of the respective clip shoulder members 14.

[0064] ​The material coil 50 cut in the feed interval has a pair of conductive terminals 18 formed at each end thereof. The linear line portion interconnecting the pair of conductive terminals 18 is subjected to a bending process to have a predetermined three-dimensional shape, and thus is transformed into one hairpin member 10 composed of the clip head member 12, the clip shoulder member 14, and the clip arm member 16.

[0065] Figure 3 is a flowchart for explaining a process of manufacturing the hairpin member of the electric machine, and Figure 4 is a hairpin member manufacturing process diagram schematically showing an overall process of manufacturing the hairpin member of the electric machine.

[0066] As shown in Figure 3 and Figure 4 , the process of manufacturing the hairpin member 10 can include an unwinding step S10, a buffering step S20, a flattening step S30, a feeding step S40, a stripping step S50, a forming step S60, an inspection step S70, and a discharging step S80.

[0067] The unwinding step S10 is a step of unwinding the material coil 50 having a rectangular cross section from the wound coil drum 40 using an unwinding device 30 and feeding the unwound material coil 50 flat from one end of the wound coil drum 40.

[0068] The buffering step S20 is a step of storing the material coil 50 unwound from the wound coil drum 40 and fed flat so that the material coil 50 is fed without delay in a unit length to manufacture the hairpin member 10. That is, the buffering step S20 is a step of sufficiently securing the length of the unwound material coil 50 capable of being fed to a predetermined length or more using a buffering device 60.

[0069] The flattening step S30 is a step of straightening the material coil 50 unwound from the wound coil drum 40 using a flattening device 62.

[0070] The feeding step S40 can be performed by a feeding device 64. The feeding device 64 holds the material coil 50 and feeds the material coil 50 in a predetermined direction by a predetermined unit length.

[0071] The stripping step S50 is a step of removing an insulating film 59 such as enamel coated on the surface of the material coil 50. The stripping step S50 can be performed by a stripping device 66 and can further include a process of grooving the conductive terminal 18 formed by removing the insulating film 59.

[0072] The forming step S60 is a step of cutting the material coil 50 into a length, i.e., a feed interval, for manufacturing each hairpin member 10 using a forming device 68 and bending the material coil 50 cut into the feed interval, thereby forming the clip head member 12, the clip shoulder member 14, and the clip arm member 16.

[0073] Inspection step S70 consists of the following steps: using inspection equipment 70 to inspect the hairpin-shaped part 10 that has undergone forming step S60 to determine whether the hairpin-shaped part 10 is a defect-free product or a defective product.

[0074] The unloading step S80 consists of the following steps: the hairpin-shaped part 10, which was determined to be a defect-free product in the inspection step S70, is fed into the unloading device 72. The hairpin-shaped part 10, which was determined to be a defect-free product, can move along the unloading device 72 and can be loaded into a predetermined position.

[0075] Feed guides 74 can be provided between the devices used to perform the above processes in order to correct the orientation and position of the material coils 50 fed between the devices.

[0076] Figure 5 This is a schematic front view of an apparatus for forming a hair clip 10 according to an embodiment of the present disclosure.

[0077] like Figure 5 As shown in the embodiments of this disclosure, the device for forming the hairpin-shaped part 10 includes a mounting frame 100, a stop 300, a cutter 200, a coil holder 500, and a pressing module 400.

[0078] The stop 300 senses whether the tip of the material coil 50 fed in one direction is in contact with the stop 300. When the tip of the material coil 50 is sensed to be in contact, the stop 300 places the tip of the material coil 50 at a predetermined point on the coil holder 500.

[0079] The material coil 50 is fed horizontally in the longitudinal direction of the X-axis. Based on... Figure 5 The material coil 50 is fed from right to left with its front end parallel to the X-axis.

[0080] A stop 300 is positioned in front of the path along which the material coil 50 is fed, and senses whether the front end of the material coil 50 is in contact with the alignment end 310. The stop 300 may further include an alignment drive unit 320 to move the alignment end 310 to a predetermined position. The alignment drive unit 320 moves in the longitudinal direction of the X-axis and aligns the material coil 50 whose front end is in contact with the alignment end 310, thereby placing the material coil 50 in the predetermined position.

[0081] The cutting element 200 is positioned at a predetermined distance from the stop 300. The cutting element 200 includes a cutting blade 210 for cutting the material coil 50, whose tip is aligned and positioned by the stop 300, to a predetermined length. The cutting blade 210 is positioned on the feed path of the material coil 50 and at a predetermined distance from the stop 300.

[0082] The coil holder 500 is positioned between the stopper 300 and the cutting member 200 on a feeding path of the material coil 50 fed in parallel with the X-axis.

[0083] The coil holder 500 supports the material coil 50 longitudinally placed in the horizontal direction to prevent the material coil 50 from being bent or sagged and allows the material coil 50 to be fed straight along a straight feeding path.

[0084] The coil holder 500 can include first and second support members 510 and 520. The coil holder 500 can include a plate-shaped member mounted on the front surface of the mounting frame 100, and the first and second support members 510 and 520 can be provided to protrude forward. The first and second support members 510 and 520 are positioned on both sides of the pressing module 400, and stably fix both sides of the processed portion of the material coil 50 in the process of processing the material coil 50.

[0085] The pressing module 400 can be a processing frame configured to press and bend the material coil 50 longitudinally placed between the stopper 300 and the cutting member 200 into a predetermined shape.

[0086] The front end of the material coil 50 is in contact with the alignment end 310 of the stopper 300. In this aligned state, the material coil 50 is cut into a predetermined length (feeding pitch) by the cutting member 200, and the cut material coil 50 is placed on the coil holder 500.

[0087] The first and second support members 510 and 520 of the coil holder 500 are provided adjacent to the pressing module 400 on both sides of the pressing module 400, and the pressing module 400 is disposed between the first and second support members 510 and 520.

[0088] The pressing module 400 includes a die seat 800, a main press 410, and a side press 420. The die seat 800 is fixed to the front surface of the coil holder 500 and is mounted between the first and second support members 510 and 520. At least a portion of the outer surface of the die seat 800 exposed toward the front surface of the coil holder 500 can be formed as a die processing surface 820.

[0089] The main press 410 presses the material coil 50 placed on the coil holder 500 toward the fixed die seat 800 in the -Z-axis direction and the +Y-axis direction, thereby transforming the material coil 50 into a hairpin-shaped member 10 having a chuck member 12 and a chuck shoulder member 14.

[0090] The main press 410 includes a main lifting unit 414, an upper press body 600, and a center press body 700.

[0091] The main lifting unit 414 ascends and descends in the up-and-down direction on the front surface of the installation frame 100. In an embodiment of the disclosure, the main lifting unit 414 can ascend and descend due to rotational motion of the driving cam shaft 412 being converted into up-and-down linear reciprocating motion. A cam coupling hole 416 can be formed in the main lifting unit 414, and the driving cam shaft 412 can be coupled in the cam coupling hole 416 in the main lifting unit 414. Rotational motion of the driving cam shaft 412 is converted into ascending and descending motion of the main lifting unit 414. The upper pressing body 600 is coupled to the main lifting unit 414 to ascend and descend in the ±Z-axis direction together with the main lifting unit 414, thereby pressing the material coil 50 toward the mold seat 800 in the -Z-axis direction.

[0092] The central pressing body 700 presses the material coil 50 toward the mold seat 800 in the +Y-axis direction.

[0093] In addition, the side press 420 presses both sides of the material coil 50 located at a position deviated from the mold seat 800 and the main press 410 from the top downward, thereby forming a pair of the clamp arm pieces 16.

[0094] The side press 420 includes a pair of side motors 422, a pair of side lifting units 424, a pair of side pressing blocks 426, and a pair of side lifting blocks 428 disposed on both sides of the main press 410.

[0095] The side lifting unit 424 ascends and descends in the up-and-down direction as the side motor 422 operates. The side pressing block 426 is coupled to the side lifting unit 424 to ascend and descend as the side lifting unit 424 ascends and descends.

[0096] The pair of side pressing blocks 426 installed on both sides of the main press 410 move the side lifting blocks 428 located on both sides of the main press 410 adjacent to the main press 410 in the up-and-down direction.

[0097] One of the pair of side lifting blocks 428 is located in a space between the main press 410 and the first support member 510 to be ascendable and descendable in the up-and-down direction, and the other of the pair of side lifting blocks 428 is located in a space between the main press 410 and the second support member 520 to be ascendable and descendable in the up-and-down direction.

[0098] The middle portion of the material coil 50 is pressed in the ±Y-axis direction and the ±Z-axis direction between the main press 410 and the mold seat 800 and thus is transformed into the clamp head piece 12 and the clamp shoulder piece 14. In addition, the side portions of the material coil 50 on both sides of the periphery of the clamp head piece 12 and the clamp shoulder piece 14 are pressed from the top downward by the side lifting blocks 428 of the side press 420 and thus are transformed into the clamp arm pieces 16.

[0099] Figure 6is an exploded perspective view showing the upper press body 600 in the apparatus for forming the hairpin-like member 10 according to an embodiment of the disclosure, and Figure 7 is a perspective view showing the upper press body 600 in the apparatus for forming the hairpin-like member 10 according to an embodiment of the disclosure.

[0100] As shown in Figure 6 and Figure 7 The upper press body 600 can be divided into an upper coupling knob 610, a shoulder piece block 620, and a base block 630. That is, the upper coupling knob 610, the shoulder piece block 620, and the base block 630 are combined to form the upper press body 600.

[0101] The base block 630 includes a base machining surface 632, a first coupling portion 634, and a second coupling portion 636.

[0102] The rear surface (+Y-axis direction) of the base block 630 can be formed as a flat surface, and the base machining surface 632 can be a three-dimensional surface protruding in the forward (-Y-axis direction), that is, in a direction opposite to the rear surface formed as a flat surface.

[0103] The base machining surface 632 is formed in such a manner that the height of the protruding portion thereof and the thickness of the protruding portion from the rear surface gradually decrease from the center portion thereof to both sides thereof. That is, as shown in the drawing, the base machining surface 632 is a three-dimensional surface oriented in the -Y-axis direction, and has a predetermined curved surface, the height and thickness of which gradually decrease from the center thereof to both sides thereof.

[0104] The first coupling portion 634 and the second coupling portion 636 are disposed above the base machining surface 632.

[0105] The first coupling portion 634 can be formed as a flat surface facing the front (-Y-axis direction), and a plurality of fastening holes through which a fastening member such as a bolt is fastened so as to be coupled to the upper coupling knob 610 contacting the front surface of the first coupling portion 634 can be formed in the first coupling portion 634.

[0106] The second coupling portion 636 can be located below the first coupling portion 634 and on the base machining surface 632, and can be disposed in the form of a groove between the first coupling portion 634 and the base machining surface 632.

[0107] The shoulder piece block 620 is coupled to the front surface of the second coupling portion 636.

[0108] The shoulder block 620 is coupled to the second coupling portion 636. A front surface of the shoulder block 620 is a shoulder processing surface 622 formed as a three-dimensional surface protruding more forward than the base processing surface 632. An upper end of the shoulder block 620 is formed as a horizontal surface. The vertical length of the shoulder block 620 gradually increases downward from the center thereof to both sides thereof.

[0109] The upper coupling knob 610 is coupled to the first coupling portion 634 in a state in which at least a portion of the upper coupling knob 610 is in contact with the upper surface of the shoulder block 620 formed as a flat surface. In addition, the upper end portion of the upper coupling knob 610 can be coupled to the main lifting unit 414.

[0110] The upper coupling knob 610, the shoulder block 620, and the base block 630 can be coupled to each other to form the upper pressing body 600, and can be separated from each other to be independently replaced.

[0111] Figure 8 is a longitudinal sectional view for explaining the pressing module 400 in the apparatus for shaping the hairpin 10 according to an embodiment of the disclosure.

[0112] As Figure 8 shown, the center pressing body 700 includes a center processing surface 720 and a center coupling knob 710.

[0113] The center processing surface 720 is a three-dimensional surface facing the base processing surface 632 described above and oriented in the +Y-axis direction.

[0114] The center processing surface 720 is a surface having a shape corresponding to the base processing surface 632, and the center processing surface 720 and the base processing surface 632 are formed to be in contact with each other without a gap in a state of facing each other.

[0115] The center pressing body 700 can linearly reciprocate in the ±Y-axis direction while passing through the mounting frame 100 and the coil holder 500 in the ±Y-axis direction.

[0116] The center coupling knob 710 is provided opposite to the center processing surface 720. The center coupling knob 710 extends through the mounting frame 100 and the coil holder 500 in the -Y-axis direction.

[0117] The center coupling knob 710 can be connected to a driving unit. The center processing surface 720 is provided to linearly reciprocate forward and backward in the ±Y-axis direction.

[0118] The mold seat 800 includes a mold processing surface 820, which is a three-dimensional surface oriented in the same direction as the center processing surface 720, and a mold fixing surface 810 formed as a flat surface at a position opposite to the mold processing surface 820.

[0119] The mold fixing surface 810 can be in contact and coupled with the front surface of the mounting frame 100 or the front surface of the coil holder 500.

[0120] Figure 9 and Figure 10 are views showing a process of machining the coil 50 of the material into the shape of the hairpin 10 by the apparatus for forming the hairpin 10 according to an embodiment of the disclosure.

[0121] As shown in Figure 9 and Figure 10 The front end of the coil 50 of the material fed in the +X-axis direction is aligned in place by the stopper 300, and then the coil 50 of the material is cut into a predetermined length, i.e., a feeding interval, by the cutter 200. The cut coil 50 of the material is placed on the front surface of the coil holder 500 in the X-axis longitudinal direction.

[0122] The upper pressing body 600 is initially lowered toward the mold base 800, so that the coil 50 of the material is located in front of the base processing surface 632 of the upper pressing body 600.

[0123] The center pressing body 700 presses the middle portion of the coil 50 of the material in the +Y-axis direction to process the coil 50 of the material between the base processing surface 632 and the center processing surface 720. In an embodiment of the disclosure, the clip head 12 of the hairpin 10 can be formed through this process.

[0124] The center pressing body 700 is moved backward to form a step with the mold base 800. The length of the step formed between the backwardly moved center pressing body 700 and the mold base 800 can correspond to the thickness of the coil 50 of the material.

[0125] The mold base 800 forms a lower processing frame, and the center processing surface 720 of the center pressing body 700 forms a processing frame on the X-Z plane. In this state, the upper pressing body 600 is lowered again to bend the both sides of the clip head 12 of the coil 50 of the material downward, thereby forming the clip shoulder 14.

[0126] In this way, the clip head 12 and the clip shoulder 14 are formed by the main pressing machine 410 and the mold base 800. The side pressing machine 420 is lowered to press the both sides of the coil 50 of the material located at a position deviated from the main pressing machine 410 and the mold base 800, thereby forming a pair of clip arm 16 extending downward in parallel with each other.

[0127] After the material coil 50 is completely processed into the shape of the hairpin 10, the side press 420 and the upper press 600 are raised, and the center press 700 is moved in the +Y axis direction, thereby allowing the hairpin 10 placed on the mold seat 800 to be separated from the hairpin forming apparatus according to the embodiment of the present disclosure and freely fall.

[0128] As is apparent from the above description, according to the present disclosure, the cutting member for cutting the material coil is small in volume and simple in structure, thereby more rapidly and accurately cutting the material coil.

[0129] According to the present disclosure, each of the press and the mold for processing the material coil is composed of a plurality of components that are detachably coupled to each other. Accordingly, only the worn processing surface or the component that needs to be replaced is selectively replaced, thereby reducing the time and cost required for maintenance of the press and the mold.

[0130] According to the present disclosure, the material coil is processed in the front-rear direction and the up-down direction, such that each portion constituting the hairpin is sequentially formed, thereby making it possible to reduce shape variation of the manufactured hairpin and to prevent the bent portion of the hairpin from being damaged.

[0131] Effects achievable by the present disclosure are not limited to the above-mentioned effects, and other effects not mentioned herein will be clearly understood by those skilled in the art from the above description.

[0132] Embodiments of the present disclosure have been described above with reference to the accompanying drawings. However, the embodiments are presented only for illustrative purposes, and the present disclosure is not limited to the above-described embodiments and drawings.

[0133] It will be apparent to those skilled in the art that various changes in form and details can be made without departing from the scope and spirit of the present disclosure. It will be understood that the embodiments described herein are part of the present disclosure.

[0134] The embodiments described herein should not be construed as limiting the scope of the present disclosure. The scope of the present disclosure should be defined by the technical spirit described in the appended claims.

[0135] In addition, although not all the roles or effects of the configuration according to the embodiments are explicitly described, it is obvious that the roles or effects predictable from the configuration should also be considered to fall within the spirit and scope of the present disclosure.

Claims

1. An apparatus for forming a hairpin-shaped part for an electric motor, the apparatus comprising: A stopper senses contact with the tip of a material coil that is fed in one direction and aligns the tip of the material coil at a predetermined position. A cutting element, including a cutting blade positioned at a predetermined distance from the stop, the cutting element cuts the material coil aligned with the stop to a predetermined length; A coil holder is disposed between the stop and the cutter, the coil holder allowing the material coil to be placed on the coil holder; as well as A pressing module for pressing and bending the material coil placed on the coil holder.

2. The device according to claim 1, wherein, The suppression module includes: A mold base is fixed to the front surface of the coil holder, and a mold processing surface is formed on a portion of the outer surface of the mold base; The main pressing machine presses the material coil toward the mold base to form a chuck and a shoulder; and A side press presses both sides of a material coil that extends beyond the mold base and the main press press, thereby pressing from top to bottom to form a pair of clamping arms.

3. The device according to claim 2, wherein, The main press includes: The main lifting unit rises and falls as the drive camshaft rotates; The upper pressing body is connected to the lower end of the main lifting unit so as to rise and fall vertically above the mold base; and A central pressing body is disposed between the mold base and the upper pressing body. The central pressing body presses the material coil forward toward the upper pressing body to form the chuck.

4. The device according to claim 3, wherein, The upper pressing body includes: The base block includes a rear surface, a base machined surface, a first connecting portion, and a second connecting portion. The rear surface is flat. The base machined surface is formed on the front surface of the base block in such a way that the height and front-to-back thickness of the base machined surface gradually decrease from the center of the base machined surface to both sides of the base machined surface. The first connecting portion and the second connecting portion are disposed above the base machined surface. A shoulder block, connected to the second connecting portion, the shoulder block including a front surface protruding forward beyond the base machined surface and a horizontally formed upper end, the shoulder block being formed such that its vertical length gradually increases downward from the center of the shoulder block towards both sides; and The upper connecting knob is connected to the first connecting part and contacts the upper surface of the shoulder block. The upper end of the upper connecting knob is connected to the main lifting unit.

5. The device according to claim 4, wherein, The upper pressing body and the central pressing body of the main pressing machine are detachably connected.

6. The device according to claim 4, wherein, The base block and shoulder block of the upper pressing body can be replaced individually.

7. The device according to claim 4, wherein, The central compression body includes: The center machining surface is formed as a three-dimensional surface corresponding to the base machining surface when facing the base machining surface; and The center connection knob extends through the coil holder and mounting frame in a direction opposite to the center machined surface.

8. The device according to claim 7, wherein, The central machined surface of the central pressing body moves back and forth through the mounting frame and the coil holder toward the base machined surface.

9. The device according to claim 1, wherein, The hairpin-shaped component is formed by processing a coil of linear material.

10. A vehicle including an electric motor having a hairpin-shaped member formed by the apparatus according to claim 1.

11. An electric vehicle, including a motor having a hairpin-shaped member formed by the apparatus according to claim 1.

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