Coiled material stripping apparatus for manufacturing hairpins of electric vehicle motors

Abstract

A web stripping apparatus is configured to manufacture a hairpin for an electric machine of an electric vehicle. The coiled material stripping equipment comprises a base frame provided with a guide rail with a linear path; at least two peeling units configured to press both sides of the material web to remove the insulating film while moving along the guide rail; and a controller configured to control movement and operation of the peeling unit. The stripping unit comprises a first stripping unit and a second stripping unit, the first stripping unit is arranged on the upstream of the material coil feeding path, and the second stripping unit is arranged on the downstream of the first stripping unit.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of Korean Patent Application No. 10-2024-0130620, filed on September 26, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to a roll stripping apparatus for manufacturing hairpins for electric vehicle motors, and more specifically, to a roll stripping apparatus configured to remove an insulating film from a predetermined portion of the outer periphery of a material roll having a rectangular cross-section, thereby exposing a conductive core. Background Technology

[0004] The electric motor is the core component of an electric vehicle. An electric motor consists of a stator and a rotor. It is a device that uses electrical energy to generate mechanical energy by causing the rotor to rotate relative to the stator. Typically, the stator is made of highly conductive copper wire wound around it. When alternating current (AC) flows through the copper wire, a magnetic field is created around the stator. The rotor can be a steel core and / or a magnet, and it rotates under the influence of the magnetic field created around the stator. The motor converts the electrical energy supplied to the stator into kinetic energy to power the rotor's rotation.

[0005] As the volumetric density of copper wire wound on the stator increases, the efficiency and performance of the motor are improved. Therefore, copper wire can be formed into linear components with rectangular cross-sections to allow for denser winding of the copper wire on the stator.

[0006] In addition, in order to improve the performance and efficiency of motors, motors equipped with hairpin-shaped stators are widely used. These hairpin-shaped stators are made by deforming copper wires cut to a predetermined length into a hairpin shape and then installing the hairpins in stator slots.

[0007] Hair clips are manufactured by processing linear copper coils with a rectangular cross-section. A thin insulating film is coated on the surface of the linear copper coil. This insulating film can be formed by coating the surface of the copper coil with an insulating material such as enamel.

[0008] Multiple hairpins are inserted into stator slots and arranged in a carefully designed pattern. Each hairpin includes an insulating portion to prevent short circuits with adjacent hairpins and an insulating film removal portion to achieve electrical connection with the circuit.

[0009] Traditionally, hairpins are manufactured through the following process: feeding a linear copper coil in one direction, removing an insulating film from a predetermined portion of the linear copper coil, and cutting the linear copper coil in units of predetermined length based on the portion with the insulating film removed.

[0010] However, based on existing technology that cuts copper coils after removing the insulating film, it is impossible to precisely adjust the length of each hairpin and the position of the portion of the insulating film removed from each hairpin. Summary of the Invention

[0011] One aspect of this disclosure relates to a motor for electric vehicles, specifically designed to address the following problem in the prior art: when performing a process of removing an insulating film from the surface of a roll of material or a grooving process, the processing tolerances are relatively large due to the pressure of the press.

[0012] Another aspect of this disclosure aims to address the following problem in the prior art: the thickness of the insulating film removed from a material roll having a rectangular cross-section is uneven, and therefore, the portion of the material roll that undergoes the peeling and grooving process has an irregular cross-sectional shape.

[0013] Another aspect of this disclosure aims to address the following problem in the prior art: in order to prevent deterioration of processing quality due to processing debris generated during the stripping and grooving processes, the processing process must be frequently interrupted to remove the processing debris.

[0014] This disclosure is not limited to those mentioned above, and those skilled in the art will clearly understand from the following description other aspects or purposes not mentioned herein.

[0015] A roll stripping apparatus according to an embodiment of the present disclosure is configured to remove an insulating film from the surface of a material roll to manufacture a hairpin for an electric motor. The roll stripping apparatus may include: a base frame with guide rails disposed on its upper surface; at least two stripping units configured to move along the guide rails, the at least two stripping units being configured to face and compress both sides of a horizontally fed material roll to remove the insulating film coated on the material roll; and a controller configured to control the movement and operation of the at least two stripping units on the base frame, wherein the at least two stripping units include: a first stripping unit disposed upstream of a material roll feed path; and a second stripping unit disposed downstream of the first stripping unit.

[0016] In some respects, the guide rail appropriately has a straight path.

[0017] According to another aspect, a roll-type stripping apparatus for manufacturing hairpins according to an embodiment of the present disclosure is an apparatus for removing an insulating film from the surface of a material roll to expose a conductive core, and includes: a base frame with a guide rail disposed on its upper surface, the guide rail having a straight path; at least two stripping units configured to be movable along the guide rail, the at least two stripping units being configured to face and squeeze both sides of a horizontally fed material roll to remove an insulating film coated on the material roll; and a controller configured to control the movement and operation of the at least two stripping units on the base frame, wherein the at least two stripping units include a first stripping unit and a second stripping unit, the first stripping unit being disposed upstream of the material roll based on the feed path, the first stripping unit being configured to squeeze the upper and lower portions of the material roll to remove predetermined portions of the insulating film from the upper and lower surfaces of the material roll, and the second stripping unit being disposed downstream of the first stripping unit, the second stripping unit being configured to squeeze both sides of the material roll to remove predetermined portions of the insulating film from both side surfaces of the material roll.

[0018] In a roll stripping device for manufacturing hairpins according to an embodiment of the present disclosure, each of the first stripping unit and the second stripping unit may include: a main board movably coupled to a guide rail; an operation box connected to the upper side of the main board, the operation box being equipped with a vise retainer configured to reciprocate along a predetermined linear path according to the operation of a servo motor; a fixed mold fixed to the main board, the fixed mold having a processing unit disposed on one of its surfaces; and a movable mold connected to the vise retainer to repeatedly perform operations of approaching and moving away from the processing unit.

[0019] In the roll stripping apparatus for manufacturing hairpins according to an embodiment of the present disclosure, a first stripping unit can squeeze two opposing surfaces of the material roll in a Z-axis linear direction perpendicular to the X-axis linear direction of the conveying material roll, and a second stripping unit can squeeze two opposing surfaces of the material roll in a Y-axis linear direction perpendicular to both the X-axis linear direction and the Z-axis linear direction.

[0020] In a roll stripping apparatus for manufacturing hair clips according to an embodiment of the present disclosure, the movable mold may include a processing tool disposed on a surface of the movable mold facing the processing unit, so as to squeeze the material roll together with the processing unit to remove the insulating film.

[0021] In a roll stripping apparatus for manufacturing hairpins according to an embodiment of the present disclosure, each of the first stripping unit and the second stripping unit may further include a pair of vises configured to fix the roll of material when the distance between the movable mold and the fixed mold is less than a predetermined distance, and the processing unit and processing tools may be located between the pair of vises.

[0022] In a roll stripping device for manufacturing hairpins according to an embodiment of the present disclosure, the pair of vises may include a pair of lifting blocks and a pair of alignment blocks, wherein the pair of lifting blocks are connected to a movable mold, a processing tool is disposed between the pair of lifting blocks, the pair of alignment blocks are disposed at a fixed mold so as to correspond to the pair of lifting blocks respectively, and a processing unit is disposed between the pair of alignment blocks.

[0023] In a roll-to-roll stripping apparatus for manufacturing hairpins according to an embodiment of the present disclosure, each of the alignment blocks may include: a holding block having a roll-to-roll feed path formed therein as a channel through which the material roll passes; a reference block configured to contact one side of the holding block; and a pressing block configured opposite to the reference block, thereby contacting the other side of the holding block. When the lifting block approaches the alignment block, the lifting block may press the reference block and the pressing block so that the reference block and the pressing block press the holding block from both sides.

[0024] In a roll stripping apparatus for manufacturing hairpins according to an embodiment of the present disclosure, each of the alignment blocks may further include: a reset unit configured to push the reference block and the extrusion block back to their original positions in opposite directions when the gap between the reference block and the extrusion block is less than a predetermined gap.

[0025] In a roll stripping apparatus for manufacturing hairpins according to an embodiment of the present disclosure, a processing unit may include at least one processing blade and a cavity formed around the at least one processing blade, the cavity serving as a channel for discharging debris.

[0026] In a roll stripping apparatus for manufacturing hairpins according to an embodiment of the present disclosure, the movable mold may include at least one air hole formed in the movable mold to inject air into the cavity.

[0027] The vehicle may include an electric motor having a hairpin manufactured using a roll-to-roll peeling device.

[0028] Electric vehicles may include an electric motor having a hairpin manufactured using a roll-to-roll peeling device. Attached Figure Description

[0029] The above and other objects, features and advantages of this disclosure will become clearer from the following detailed description taken in conjunction with the accompanying drawings, wherein:

[0030] Figure 1 This is a view of a motor hairpin manufactured by a roll-to-roll peeling apparatus according to an embodiment of the present disclosure;

[0031] Figure 2 It is a three-dimensional diagram illustrating the material roll wound on a spool;

[0032] Figure 3It is a flowchart illustrating the process of manufacturing a hair clip for an electric motor;

[0033] Figure 4 This is a schematic diagram illustrating the process of manufacturing a hair clip using a roll-to-roll peeling apparatus according to an embodiment of the present disclosure.

[0034] Figure 5 This is a front view of a roll-to-roll peeling apparatus according to an embodiment of the present disclosure;

[0035] Figure 6 This is a perspective view of a roll-to-roll peeling apparatus according to an embodiment of the present disclosure;

[0036] Figure 7 This is a schematic diagram illustrating the operating state of the vise clamp in the roll stripping device according to an embodiment of the present disclosure;

[0037] Figure 8 This is a bottom perspective view of the movable mold in the roll stripping apparatus according to an embodiment of the present disclosure;

[0038] Figure 9 This is a block diagram schematically illustrating the path of air injection into the processing unit in a roll-to-roll peeling apparatus according to an embodiment of the present disclosure; and

[0039] Figure 10 and Figure 11 This is a schematic view illustrating the process of forming conductive terminals at the ends of a material roll using a roll-to-roll peeling apparatus according to an embodiment of the present disclosure. Detailed Implementation

[0040] It is understood that, as used herein, the terms “vehicle” or “of a vehicle” or other similar terms generally include motor vehicles, such as passenger cars including sport utility vehicles (SUVs), buses, trucks, various commercial vehicles, watercraft including various ships and vessels, aircraft, etc., and include hybrid vehicles, electric vehicles, plug-in hybrid electric vehicles, hydrogen-powered vehicles, and other vehicles using alternative fuels (e.g., fuels derived from resources other than petroleum). As described herein, a hybrid vehicle is a vehicle with two or more power sources, such as a gasoline and electric dual-power vehicle.

[0041] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit this disclosure. Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” as used herein are intended to also include the plural forms. It will be further understood that when the terms “comprising” and / or “including” are used in this specification, they indicate the presence of the stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The term “and / or” as used herein includes any one and all combinations of one or more of the associated listed items. Throughout this specification, unless explicitly stated otherwise, the word “comprising” and variations such as “including” or “containing” will be understood to imply inclusion of the stated elements without excluding any other elements. Additionally, the terms “unit,” “device,” “component,” and “module” described in the specification refer to a unit for performing at least one function and operation, and can be implemented by hardware components or software components and combinations thereof.

[0042] Furthermore, the control logic of this disclosure can be implemented as a non-transitory computer-readable medium containing executable program instructions that are executed by a processor, controller, etc. Examples of computer-readable media include, but are not limited to, ROM, RAM, optical disc (CD)-ROM, magnetic tape, floppy disk, flash drive, smart card, and optical data storage device. The computer-readable medium can also be distributed across a networked computer system, thereby being stored and executed in a distributed manner, for example, via a telematics server or a controller area network (CAN).

[0043] In the following, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings.

[0044] In the following description of the embodiments disclosed in this specification, detailed descriptions of such known features and configurations will be omitted where such inclusions may make the subject matter of the embodiments disclosed herein quite unclear.

[0045] Furthermore, the accompanying drawings are provided merely to better understand the embodiments disclosed in this specification, and not to limit the technical ideas disclosed in this specification.

[0046] It should be understood that when a component is referred to as being "connected to" or "attached to" another component, the component may be directly connected to or attached to the other component, or there may be an intermediate component.

[0047] The first direction X, the second direction Y, and the third direction Z described in this article refer to the various dimensions and directions of the three-dimensional coordinate system used to describe the three-dimensional shape. Therefore, the first direction X, the second direction Y, and the third direction Z can be represented by arrows that intersect each other perpendicularly at a point in space.

[0048] This disclosure relates to an apparatus 66 for removing an insulating film 59, the apparatus 66 being used in the manufacture of a hairpin 10 for an electric motor.

[0049] Figure 1 This is a view illustrating the hairpin 10 of an electric motor according to an embodiment of the present disclosure. The hairpin 10 is manufactured using a device 66 for removing the insulating film 59. Figure 2 This is a three-dimensional view illustrating the material roll 50 wound on the spool 40.

[0050] Reference Figure 1 and Figure 2 The motor includes a stator 20 and a rotor.

[0051] Typically, the stator 20 is the fixed component of the motor. The material roll 50 can be wound onto the stator core 22 in a predetermined direction.

[0052] As shown in the figure, the material roll 50 can have the shape of a hairpin 10. Multiple stator cores 22 can be provided, and the multiple stator cores 22 can be arranged at regular intervals. Stator slots 24 are formed between the stator cores 22. The material roll 50 can be cut to a predetermined length, and the cut material roll can be transformed into a hairpin 10. Each of the multiple hairpins 10 can be accommodated in a corresponding one of the stator slots 24.

[0053] As described above, the hair clip 10, manufactured by cutting and processing the material roll 50, can be mounted onto the stator 20 of the motor.

[0054] When an electric current is applied to the hairpin 10, a magnetic field is formed around the stator 20. Then, under the influence of the magnetic field formed around the stator 20, the rotor rotates relative to the stator 20.

[0055] The roll stripping device 66 according to an embodiment of the present disclosure can be used in the process of manufacturing hair clip 10.

[0056] The hair clip 10 is manufactured by processing a material roll 50 cut to a predetermined length. Optionally, in some embodiments of this disclosure, in order to manufacture the hair clip 10, bending, peeling and grooving processes may be performed on some portions of the material roll 50 in advance, and then the process of cutting the material roll 50, which has undergone the above processes, may be performed.

[0057] The material roll 50 is formed into a linear conductor with a rectangular cross-section.

[0058] In detail, the material roll 50 includes a conductive core 58 made of conductive material and an insulating film 59 coated on the surface of the conductive core 58. The conductive core 58 may be a linear copper component with a rectangular cross-section, and the insulating film 59 may be an insulating material, such as enamel, coated on the surface of the conductive core 58 as a layer with a predetermined thickness.

[0059] The hair clip 10 is manufactured by cutting a linear material roll 50 to a predetermined length, and forming a pair of conductive terminals 18 at corresponding ends of the hair clip 10. The pair of conductive terminals 18 are formed at corresponding ends of the hair clip 10 and have a predetermined length. The conductive terminals 18 are portions of the material roll 50 to which the insulating film 59 has been removed, exposing portions of the conductive core 58 to the outside, thereby serving as terminals for electrical connection.

[0060] The hair clip 10 can be divided into a pin head 12, a pin shoulder 14, a pin arm 16, and the aforementioned conductive terminal 18.

[0061] The pin 12 is the central part of the hairpin 10 and corresponds to the vertex part that is bent at a predetermined angle.

[0062] The pin head 12 is the point where a pair of pin shoulders 14 intersect each other. The pair of pin shoulders 14 corresponds to the linear portions extending to both sides from the pin head 12.

[0063] Based on such Figure 1 The pin head 12 is shown with its sharp curved portion facing upwards. In the plan view and front view, the pair of pin shoulders 14 can be aligned with the two sides of a virtual triangle that forms an angle between the pair of pin shoulders 14, with the pin head 12 at the vertex of the angle.

[0064] A pin arm 16 is formed at the end of the corresponding pin shoulder 14. Based on Figure 1 The pin arm 16 is a linear portion that extends in a straight line in the vertical direction, and a conductive terminal 18 is formed at the lower end of the corresponding pin arm 16.

[0065] The two pin arms 16 can be set parallel to each other.

[0066] like Figure 2 As shown, the material roll 50 used to manufacture the hair clip 10 is a linear component with a rectangular cross-section and can be stored and transported while wound on a spool 40.

[0067] The winding spool 40 may include a spool core 44 having a cylindrical shape, a shielding plate mounted on the respective ends of the spool core 44, and a central hole 42 forming a through hole passing through the center of the spool core 44 in the longitudinal direction of the spool core 44.

[0068] The material roll 50 with a rectangular cross-section includes a long side portion 52 and a short side portion 54, the long side portion 52 having a relatively long length and the short side portion 54 having a relatively short length.

[0069] The pin shoulders 14 are portions that extend in a straight line from the pin head 12 to both sides. That is, the pin shoulders 14 extend from the pin head 12 to both sides at a predetermined angle.

[0070] The pin arms 16 are linear members extending from the ends of the corresponding pin shoulders 14. The pin arms 16 are arranged parallel to each other, and conductive terminals 18 are formed at the ends of the corresponding pin arms 16.

[0071] In detail, the hair clip 10 can be manufactured by processing a roll of material 50 cut to a predetermined length.

[0072] A portion of the insulating film 59 is removed from both ends of the material roll 50 cut to a predetermined length, thereby forming conductive terminals 18 at both ends of the material roll 50.

[0073] In addition, the straight portion between the pair of conductive terminals 18 undergoes a bending process to achieve a predetermined three-dimensional shape, thereby forming a pin head 12, a pin shoulder 14, and a pin arm 16. Through the above process, a hair clip 10 is manufactured.

[0074] Figure 3 It is a flowchart illustrating the process of manufacturing the hairpin 10 for the motor, and Figure 4 This is a schematic diagram illustrating the process of manufacturing a hair clip 10 for an electric motor using an apparatus 66 for removing the insulating film 59, according to an embodiment of the present disclosure.

[0075] like Figure 3 and Figure 4 As shown, the process of manufacturing hair clip 10 may include unwinding step S10, buffering step S20, leveling step S30, feeding step S40, peeling step S50, forming step S60, inspection step S70 and discharge step S80.

[0076] The unwinding step S10 consists of the following steps: using the unwinding device 30 to unwind the material roll 50 with a rectangular cross-section from the winding shaft 40, and conveying the unwound material roll 50 in a straight line from one end of the winding shaft 40.

[0077] The buffering step S20 involves storing the material roll 50 unwound from the winding spool 40 and fed in a straight line, such that the material roll 50 is fed without delay at a unit length for manufacturing the hair clip 10. In other words, the buffering step S20 involves using the buffering device 60 to sufficiently ensure that the length of material that can be fed onto the unwound material roll 50 is a predetermined length or longer.

[0078] The leveling step S30 consists of the following steps: using the leveling device 62 to straighten the material roll 50 unwound from the winding shaft 40.

[0079] The feeding step S40 can be performed by the feeding device 64. The feeding device 64 holds the material roll 50 and conveys the material roll 50 in a predetermined direction at a predetermined unit length.

[0080] The stripping step S50 comprises the following steps: removing an insulating film 59, such as enamel, coated on the surface of the material roll 50. The stripping step S50 can be performed by a stripping device 66 and may further include a grooving process for the conductive terminals 18, which are formed by removing the insulating film 59.

[0081] The forming step S60 consists of the following steps: cutting the material roll 50 into a “set length” and bending the material roll 50 cut into the set length using the forming device 68 to form the pin head 12, pin shoulder 14 and pin arm 16, wherein the set length is the length on the material roll 50 used to manufacture each hairpin 10.

[0082] The inspection step S70 is the following steps: using inspection equipment 70 to inspect the hair clip 10 that has undergone forming step S60 to determine whether the hair clip 10 is a good product or a defective product.

[0083] The discharge step S80 consists of the following steps: the hair clips 10 that have been determined to be good products in the inspection step S70 are conveyed to the discharge device 72. The hair clips 10 that have been determined to be good products are conveyed along the discharge device 72 to a predetermined position.

[0084] To correct the orientation and position of the material roll 50 being conveyed between devices, a feed guide 74 can be provided between the devices used to perform the corresponding processes described above.

[0085] Figure 5 This is a front view of an apparatus 66 for removing insulating film 59 according to an embodiment of the present disclosure, and Figure 6 This is a perspective view of an apparatus 66 for removing insulating film 59 according to an embodiment of the present disclosure.

[0086] like Figure 5 and Figure 6 As shown, the apparatus 66 for removing the insulating film 59 according to an embodiment of the present disclosure may include a base frame 100, a stripping unit, and a controller.

[0087] The base frame 100 is a structure that is firmly fixed to the floor, and the upper surface of the base frame can be flat in the horizontal direction.

[0088] The base frame 100 includes a guide rail 110, which is formed to extend in one direction.

[0089] The guide rail 110 may include a pair of straight guide rails arranged parallel to each other on the base frame 100 and forming a straight path.

[0090] In embodiments of this disclosure, the guide rail 110 is disposed on the upper surface of the base frame 100 and is formed to be straight in the longitudinal direction of the X-axis.

[0091] The peeling unit is connected to the guide rail 110. The peeling unit may include a first peeling unit 200 and a second peeling unit 202.

[0092] Each of the first peeling unit 200 and the second peeling unit 202 is configured to reciprocate linearly along the guide rail 110 and face and press against two opposite sides of the material roll 50 that is fed horizontally in the X-axis direction to remove the insulating film 59 coated on the material roll 50.

[0093] Based on the feeding path of the material roll 50 fed longitudinally along the X-axis, the first peeling unit 200 is located upstream of the second peeling unit 202. The second peeling unit 202 is located downstream of the first peeling unit 200.

[0094] The first peeling unit 200 squeezes the fed material roll 50 from above and below to remove a predetermined portion of the insulating film 59 from the upper and lower surfaces of the material roll 50.

[0095] The second peeling unit 202 is configured such that its roll feed path 542 lies on the same straight line as the roll feed path 542 of the first peeling unit 200, wherein the roll feed path 542 of the second peeling unit 202 is the path along which the material roll 50 is fed in the longitudinal direction of the X-axis. However, based on the virtual straight line along which the roll feed path 542 extends, the second peeling unit 202 is mounted on the guide rail 110 and oriented perpendicular to the first peeling unit 200.

[0096] The second stripping unit 202 extrudes the fed material roll 50 from the left and right sides to remove a predetermined portion of the insulating film 59 from the left and right surfaces of the material roll 50.

[0097] The controller is mounted on the base frame 100 and controls the movement and operation of the first peeling unit 200 and the second peeling unit 202.

[0098] The first peeling unit 200 and the second peeling unit 202 are mounted on the motherboard 210, which is connected to the guide rail 110.

[0099] The motherboard 210 is connected to the feed motor 120 and, under the control of the controller, moves linearly back and forth on the path guided by the guide rail 110.

[0100] Each of the first stripping unit 200 and the second stripping unit 202 can be mounted on a corresponding one of the two main boards 210. The controller controls the feed motor 120, thereby adjusting the position of the first stripping unit 200 and the second stripping unit 202 and the gap between them.

[0101] In embodiments of this disclosure, the description of the configuration and connection relationship of the first peeling unit 200 can also be applied to the second peeling unit 202. However, the first peeling unit 200 and the second peeling unit 202 are mounted to extrude the material roll 50 in the vertical and horizontal directions, respectively.

[0102] In detail, the first peeling unit 200 presses the lower surface of the material roll 50 from below along the +Z axis direction and presses the upper surface of the material roll 50 from above along the -Z axis direction, thereby removing a predetermined portion of the insulating film 59 from the lower and upper surfaces of the material roll 50.

[0103] The second peeling unit 202 is disposed downstream of the first peeling unit 200 and is configured to allow the material roll 50, which has already passed through the roll feed path 542 of the first peeling unit 200, to pass in a straight line through the roll feed path 542 formed in the second peeling unit 202. Furthermore, based on the feeding direction of the material roll 50, the second peeling unit 202 extrudes the right surface of the material roll 50 from the right side along the +Y axis direction and extrudes the left surface of the material roll 50 from the left side along the -Y axis direction, thereby removing a predetermined portion of the insulating film 59 from the right and left surfaces of the material roll 50.

[0104] The first stripping unit 200 may include a main board 210, an operation box 230, a fixed mold 400, and a movable mold 300.

[0105] The motherboard 210 is connected to the guide rail 110 and moves along the straight path of the guide rail 110. The motherboard 210 can be moved by the feed motor 120 mounted on the substrate.

[0106] The motherboard 210 is a structure that moves along the guide rail 110. At least two motherboards 210 can be connected to the upper side of the guide rail 110.

[0107] The first stripping unit 200 can be installed on the motherboard 210 located upstream of another motherboard 210, and the second stripping unit 202 can be installed on the motherboard 210 located downstream of another motherboard 210.

[0108] The operating box 230 provided at the first stripping unit 200 includes a vise retainer 220 and a servo motor 240. The vise retainer 220 is configured to rise and fall, and the servo motor 240 is configured to provide a driving force that allows the vise retainer 220 to reciprocate linearly relative to the operating box 230.

[0109] The movable die 300 is connected to the vise retainer 220 and moves as the vise retainer 220 moves. The movable die 300 includes a handle 310, a main frame 320, a secondary frame 330, a machining tool 340, and a coil guide 350.

[0110] The main frame 320 and the sub-frame 330 support the machining tool 340 connected to their lower surfaces and are made of a material with sufficiently high rigidity so that they will not be deformed or damaged by the forces acting between the vise retainer 220 and the fixed mold 400.

[0111] The main frame 320 and the sub-frame 330 can be securely connected to each other, and the handle 310 can extend upward from the main frame 320 and / or the sub-frame 330.

[0112] Handle 310 is attached to vise retainer 220. Movable mold 300 is secured to vise retainer 220 via handle 310, thereby moving together with vise retainer 220.

[0113] Multiple guide holes 360 can be formed in the main frame 320. In embodiments of this disclosure, four guide holes 360 can be formed at a position adjacent to the outermost edge of the main frame 320.

[0114] Each of the guide holes 360 can be a circular through hole formed by passing through the main frame 320 in the vertical direction.

[0115] Additionally, the processing tool 340 is connected to the lower surface of the main frame 320 and / or the sub-frame 330. The processing tool 340 is configured such that its processing surface faces downwards, thereby contacting the surface of the material roll 50.

[0116] The processing tool 340 may include a processing surface that removes the insulating film 59 from a surface of the material roll 50 that is in contact with it. The processing tool 340 may be detached from the movable mold 300 for independent replacement.

[0117] The machining tool 340 can be fixed to the center of the lower surface of the main frame 320, and a pair of lifting blocks 510 constituting the vise clamp 500 can be arranged on both sides of the machining tool 340.

[0118] The lifting block 510 can be positioned at the front and rear of the processing tool 340 along the feeding direction of the material roll 50. The lifting block 510 can be detachably connected to the main frame 320.

[0119] The fixed mold 400 includes a fixed plate 410, a processing unit 420, a guide post 430, and an elastic unit 432.

[0120] The mounting plate 410 is mounted such that one surface of the mounting plate 410 faces the surface on the main frame 320 on which the machining tool 340 is mounted. The mounting plate 410 is connected to the upper side of the main board 210 so as to move together with the main board 210.

[0121] The processing unit 420 is disposed at the center of one surface of the fixed plate 410. The processing unit 420 is configured to face the processing tool 340. If the processing tool 340 reciprocates linearly along a predetermined straight path, the processing tool 340 repeatedly performs the operation of contacting and pressing the processing unit 420 and then moving away from the processing unit 420.

[0122] The processing unit 420 of the first stripping unit 200 is fixed to the fixed mold 400, such that the surface on the processing unit 420 on which the processing blade 422 is formed faces the +Z axis direction. In addition, the processing tool 340 is fixed to the movable mold 300, such that the processing surface of the processing tool 340 faces the -Z axis direction, thereby facing the surface on the processing unit 420 on which the processing blade 422 is formed.

[0123] The machining tool 340, together with the vise retainer 220 and the movable die 300, reciprocates along a predetermined straight path, with the movable die 300 reciprocating linearly relative to the operating box 230. Therefore, the machining tool 340 repeatedly approaches and moves away from the machining unit 420 along a path in the ±Y-axis linear direction, including a path in which the machining surface of the machining tool 340 contacts and presses against the surface of the machining unit 420 on which the machining insert 422 is formed.

[0124] During the process of the processing tool 340 and the processing unit 420 contacting and pressing each other, the material roll 50 is disposed between the processing tool 340 and the processing unit 420, and a portion of the insulating film 59 is removed from the material roll 50 by the two opposing surfaces of the processing tool 340 and the processing unit 420 contacting and pressing each other.

[0125] The processing unit 420 may include a plurality of processing blades 422, each of which may be arranged parallel or perpendicular to the feed path of the material roll 50. Additionally, cavities 424 are formed between the processing blades 422 as empty spaces. Processing byproducts, such as fragments of the insulating film 59 generated during the peeling and / or grooving processes, and processing debris, may be stored in the cavities 424. Byproducts such as fragments of the insulating film 59 and processing debris can be immediately discharged to the outside via a discharge path connected to the cavities 424.

[0126] Multiple guide pillars 430 are disposed on the upper surface of the fixed mold 400. The number and position of the guide pillars 430 correspond to the number and position of the multiple guide holes 360 formed in the movable mold 300. Each of the guide pillars 430 is a columnar member extending vertically upward from the upper surface of the fixed mold 400 and is made of a high-rigidity material.

[0127] Each of the plurality of guide posts 430 passes through a corresponding one of the plurality of guide holes 360. The positions of the fixed mold 400 and the movable mold 300 are aligned in the vertical direction by the insertion of the plurality of guide posts 430 into the plurality of guide holes 360.

[0128] The movable mold 300 is connected to multiple guide pillars 430, thus allowing it to move only in the ±Z axis direction.

[0129] The guide post 430 may be provided with elastic elements 432. Each of the elastic elements 432 may be implemented as a compression spring, which is arranged to surround a portion of the outer periphery of a corresponding one of the guide posts 430.

[0130] When the distance between the movable mold 300 and the fixed mold 400 is less than a predetermined distance, the elastic unit 432 applies a repulsive force between the fixed mold 400 and the movable mold 300.

[0131] The elastic unit 432 reduces impacts, vibrations, noises, etc. that may occur in the area where the processing tool 340 and the processing unit 420 are in contact with each other, in addition to the external force that performs the peeling or grooving of the material roll 50, and facilitates the process of separating the processing tool 340 from the processing unit 420.

[0132] The fixed mold 400 may further include a pair of alignment blocks 520. The pair of alignment blocks 520 are disposed on both sides of the processing unit 420, with the processing unit 420 disposed between the pair of alignment blocks 520. The alignment blocks 520 are arranged in pairs with the aforementioned lifting blocks 510 of the movable mold 300.

[0133] The lifting block 510 and the alignment block 520 that constitute the vise clamp 500 are respectively installed on the movable mold 300 and the fixed mold 400.

[0134] When the movable mold 300 approaches the fixed mold 400, and the machining surface of the machining tool 340 and the machining blade 422 of the machining unit 420 contact and compress the two opposing surfaces of the material roll 50, the vise clamp 500 firmly fixes the material roll 50.

[0135] Figure 7 This is a schematic diagram illustrating the operating state of the vise clamp 500 in the apparatus 66 for removing the insulating film 59 according to an embodiment of the present disclosure.

[0136] like Figure 7 As shown, the vise clamp 500 is configured such that the lifting block 510 mounted to the movable mold 300 and the alignment block 520 mounted to the fixed mold 400 are paired with each other.

[0137] Based on the feeding path of the material roll 50, the vise clamp 500 can be configured to be adjacent to both sides of the processing unit 420 and the processing tool 340, wherein the processing unit 420 and the processing tool 340 are disposed between the vise clamp 500, and the vise clamp 500 is used to firmly fix both ends of the material roll 50 when the processing tool 340 and the processing unit 420 contact the material roll 50 and remove the insulating film 59 from the material roll 50.

[0138] The lifting block 510, connected to the movable mold 300, includes a horizontal bar 512 that extends in a horizontal direction orthogonal to the longitudinal direction of the conveying material roll 50, and vertical bars 514 are formed on both sides to project downwards. These vertical bars 514 are connected to the horizontal bar 512. The gap between the facing surfaces of the two vertical bars 514 gradually increases in the direction away from the horizontal bar 512. The facing surfaces of the two vertical bars 514, i.e., the inclined surfaces, are contact portions 516, and the gap between these two surfaces gradually increases in the direction away from the horizontal bar 512.

[0139] Alignment block 520 is disposed on fixed plate 410. Alignment block 520 includes reference block 530, holding block 540 and pressing block 550.

[0140] The retaining block 540 forms a roll material feeding path 542 on the fixing plate 410. The roll material feeding path 542 is the space through which the material roll 50 passes. The retaining block 540 forms a roll material feeding path 542 on the fixing plate 410. The roll material feeding path 542 is a channel corresponding to the cross-section of the material roll 50.

[0141] The reference block 530 and the extrusion block 550 are disposed on both sides of the holding block 540.

[0142] The reference block 530, holding block 540, and extrusion block 550 are arranged in a row on the fixed plate 410 in this order. The reference block 530, holding block 540, and extrusion block 550 are arranged to intersect perpendicularly with a virtual straight line extending along the feed path.

[0143] The reference block 530 includes an upwardly projecting reference protrusion 532, and the extrusion block 550 includes an upwardly projecting variable protrusion 552.

[0144] As the lifting block 510 approaches, the reference protrusion 532 and the variable protrusion 552 contact the inclined surface formed by the contact portion 516 of the lifting block 510. That is, when the lifting block 510 approaches the alignment block 520, the reference block 530 and the pressing block 550 press the holding block 540 located at the center of the alignment block 520 by the reference protrusion 532 and the variable protrusion 552 that contact the contact portion 516 of the lifting block 510.

[0145] The extrusion block 550 may further include a roll retainer 554 protruding toward a roll feed path 542, the roll feed path 542 being a space defined by the retainer block 540. When the reference block 530 and the extrusion block 550 press the retainer block 540 from both sides toward the center of the retainer block 540, the roll retainer 554 can more firmly press and secure the outer periphery of the material roll 50 passing through the roll feed path 542.

[0146] A reset unit 560 may be provided between the reference block 530 and the pressing block 550. The reset unit 560 acts as a compression spring. When the lifting block 510 approaches the alignment block 520, thereby pressing the holding block 540 from both sides by the reference block 530 and the pressing block 550, the reset unit 560 is elastically compressed. When the lifting block 510 moves sufficiently away from the alignment block 520, thereby eliminating the external force, the reset unit 560 restores the gap between the reference block 530 and the pressing block 550 to its original gap.

[0147] The lifting block 510 and alignment block 520 constituting the vise clamp 500 can be made of a material with high rigidity and elasticity.

[0148] Figure 8 This is a bottom perspective view of the movable mold 300 in the apparatus 66 for removing insulating film 59 according to an embodiment of the present disclosure.

[0149] like Figure 8 As shown, the machining tool 340 is connected to the center of the lower surface of the movable mold 300. The machining tool 340 is surrounded by a pair of lifting blocks 510 and a pair of coil guides 350 on the lower surface of the movable mold 300.

[0150] The feeding path of the material roll 50 extends in the +X axis direction and is parallel to the Y-axis longitudinal direction, which is horizontally perpendicular to the virtual straight line extending along the feeding path of the material roll 50.

[0151] The lifting blocks 510, which are set on both sides of the machining tool 340, extend along two straight lines parallel to the Y-axis and are set on both sides of the machining tool 340.

[0152] In addition, the roll guide 350 is arranged adjacent to the two side surfaces of the machining tool 340 along two straight lines parallel to the X-axis.

[0153] Specifically, a feed slit 352 is formed between the pair of roll guides 350, which is the space through which the material roll 50 can be fed longitudinally. The roll guides 350 are formed on both sides of the processing tool 340 in the longitudinal direction to guide the material roll 50 so that it passes through the position corresponding to the processing tool 340.

[0154] In addition, the pair of lifting blocks 510 can be arranged on both sides of the processing tool 340 and are horizontally perpendicular to the longitudinal direction of the feed material roll 50.

[0155] Figure 9 This is a block diagram schematically illustrating the path traversed by air injected into the processing unit 420 of the apparatus 66 for removing the insulating film 59 according to an embodiment of the present disclosure.

[0156] like Figure 9 As shown, at least one air hole 332 can be formed in the main frame 320 and / or sub-frame 330 of the movable mold 300. The air hole 332 is an inlet for high-pressure air to be introduced from the outside. The air introduced into the air hole 332 can travel along a series of flow paths formed in the main frame 320 and / or sub-frame 330. The air introduced into the air hole 332 can then be discharged toward the space surrounded by the coil guide 350, which is the space facing the processing tool 340. Optionally, when the movable mold 300 approaches the fixed mold 400, such that the distance between the processing tool 340 and the processing unit 420 is equal to or less than a predetermined distance, the air introduced into the movable mold 300 through the air hole 332 can travel to a discharge nozzle provided in the space surrounded by the coil guide 350. The air is then discharged at high pressure from the discharge nozzle toward a cavity 424 formed in the processing unit 420.

[0157] The controller can execute a series of processes in which air is introduced into the vent 332, travels along the flow path, and is then discharged at high pressure toward the cavity 424.

[0158] Figure 10 and Figure 11 This is a schematic view illustrating the process of forming conductive terminals 18 at the ends of a material roll 50 by means of a device 66 for removing insulating film 59 according to an embodiment of the present disclosure.

[0159] As shown in the figure, the peeling device 66 according to an embodiment of the present disclosure is a device for removing the insulating film 59 from a predetermined portion of a material roll 50.

[0160] In particular, when the linear material roll 50 has a rectangular cross-section, the insulating film 59 can be removed corresponding to the cross-section at the corners.

[0161] The material roll 50 includes a linear conductive core 58 and an insulating film 59. The linear conductive core 58 has a rectangular cross-section and is disposed at the center of the material roll 50. The insulating film 59 is made of enamel and is coated on the outer surface of the conductive core 58 to a predetermined thickness.

[0162] As shown in the figure, the upper and lower surfaces of the material roll 50 are the long side portions 52 corresponding to the long side of the rectangle, and the left and right surfaces of the material roll 50 are the short side portions 54 corresponding to the short side of the rectangle.

[0163] In the peeling apparatus 66 according to an embodiment of the present disclosure, a first peeling unit 200 and a second peeling unit 202 are arranged sequentially, and the directions in which the movable mold 300 and the fixed mold 400 face each other in the first peeling unit 200 are set to be perpendicular to each other. That is, the direction in which the first peeling unit 200 contacts and compresses the material roll 50 is set to be 90 degrees to the direction in which the second peeling unit 202 contacts and compresses the material roll 50.

[0164] Therefore, as Figure 10 As shown in (b), the first peeling unit 200 can remove the insulating film 59 from the material roll 50 by passing through the upper and lower surfaces of the roll feed path 542, i.e., the long side portion 52. Afterwards, the material roll 50 can be conveyed from the first peeling unit 200 to the second peeling unit 202, and as shown in (b). Figure 10 As shown in (c), the insulating film 59 can be removed from the two remaining short side portions 54 of the material roll 50.

[0165] However, this is merely given as an example. In another embodiment of this disclosure, such as Figure 11 As shown, the insulating film 59 can be initially removed from the two short side portions 54 of the material roll 50 by the first peeling unit 200, and the insulating film 59 can be removed a second time from the two remaining long side portions 52 of the material roll 50 by the second peeling unit 202. It is evident from the above description that, according to this disclosure, since the two parallel surfaces of the material roll having a rectangular cross-section are processed simultaneously, the insulating film can be removed from the material roll to a uniform thickness.

[0166] According to this disclosure, since the vise clamps are positioned on both sides of the machining tool and machining mold used for machining the surface of the material roll, the material roll can be securely fixed. Therefore, machining tolerances can be reduced and machining quality can be improved.

[0167] According to this disclosure, by injecting air into the cavity in the processing unit, processing byproducts, such as processing debris separated from the material roll, can be removed immediately.

[0168] The effects achievable through this disclosure are not limited to those described above, and those skilled in the art will clearly understand from the above description other effects not mentioned herein.

[0169] Embodiments of this disclosure have been described above with reference to the accompanying drawings. However, these embodiments are merely illustrative and the disclosure is not limited to the above embodiments and drawings.

[0170] It will be apparent to those skilled in the art that various changes in form and detail may be made without departing from the scope and spirit of this disclosure. It should be understood that the embodiments described herein are part of this disclosure.

[0171] The embodiments described herein should not be construed as limiting the scope of this disclosure. The scope of this disclosure should be defined by the spirit of the technology set forth in the appended claims.

[0172] Furthermore, although not all actions or effects of the configuration according to the embodiments are explicitly described, it is evident that actions or effects predictable from the configuration should also be considered to fall within the spirit and scope of this disclosure.

Claims

1. A roll stripping apparatus for removing an insulating film from the surface of a roll of material to manufacture a hairpin for an electric motor, said roll stripping apparatus comprising: A base frame, with guide rails provided on its upper surface; At least two peeling units are configured to move along the guide rail, the at least two peeling units facing and squeezing both sides of the horizontally fed material roll to remove the insulating film coated on the material roll; as well as The controller controls the movement and operation of the at least two stripping units on the base frame. The at least two stripping units include: A first peeling unit is disposed upstream of the feeding path of the material roll; and The second stripping unit is located downstream of the first stripping unit.

2. The roll-to-roll peeling device according to claim 1, wherein, The first peeling unit squeezes the material roll to remove a predetermined portion of the insulating film from the material roll.

3. The roll-to-roll peeling device according to claim 1, wherein, The first peeling unit squeezes the upper and lower portions of the material roll to remove a predetermined portion of the insulating film from the upper and lower surfaces of the material roll.

4. The roll-to-roll peeling device according to claim 1, wherein, The second peeling unit squeezes the material roll to remove a predetermined portion of the insulating film from the material roll.

5. The roll-to-roll peeling device according to claim 1, wherein, The second peeling unit squeezes both sides of the material roll to remove a predetermined portion of the insulating film from both sides of the material roll.

6. The roll-to-roll peeling device according to claim 1, wherein, Each of the first stripping unit and the second stripping unit includes: The motherboard is movably connected to the guide rail; An operating box is connected to the upper side of the motherboard. The operating box is equipped with a vise retainer, which reciprocates along a predetermined straight path according to the operation of the servo motor. A fixed mold is attached to the main board, and a processing unit is provided on one surface of the fixed mold; and The movable mold is connected to the vise retainer to repeatedly move closer to and away from the machining unit.

7. The roll-to-roll peeling device according to claim 6, wherein, The first peeling unit presses two opposing surfaces of the material roll in the Z-axis linear direction, which is perpendicular to the X-axis linear direction of the material roll feed. The second peeling unit presses the two opposite surfaces of the material roll in the Y-axis linear direction, which is perpendicular to both the X-axis linear direction and the Z-axis linear direction.

8. The roll-to-roll peeling device according to claim 6, wherein, The movable mold includes a processing tool disposed on the surface of the movable mold facing the processing unit, so as to extrude the material roll together with the processing unit to remove the insulating film.

9. The roll-to-roll peeling device according to claim 8, wherein, Each of the first and second peeling units includes a pair of vises that clamp the material roll. The processing unit and the processing tool are located between the pair of vises.

10. The roll-to-roll peeling apparatus according to claim 9, wherein, The pair of vise clamps includes: A pair of lifting blocks are connected to the movable mold, and the processing tool is disposed between the pair of lifting blocks; and A pair of alignment blocks are disposed at the fixed mold so as to correspond to the pair of lifting blocks respectively, and the processing unit is disposed between the pair of alignment blocks.

11. The roll stripping device according to claim 10, wherein, Each of the pair of alignment blocks includes: A retaining block having a roll material feeding path formed therein, the roll material feeding path serving as a channel through which the material roll passes; A reference block is configured to contact one side of the retaining block; and The extrusion block is positioned opposite the reference block so as to contact the other side of the retaining block. As the lifting block approaches the alignment block, the lifting block presses against the reference block and the pressing block so that the reference block and the pressing block press against the holding block from both sides.

12. The roll-to-roll peeling apparatus according to claim 11, wherein, Each of the pair of alignment blocks further includes a reset unit that, when the gap between the reference block and the extrusion block is less than a predetermined gap, pushes the reference block and the extrusion block in opposite directions to their original positions.

13. The roll-to-roll peeling apparatus according to claim 6, wherein, The processing unit includes: At least one machining blade; and A cavity, formed around the at least one machining blade, serves as a channel for discharging debris.

14. The roll stripping device according to claim 13, wherein, The movable mold includes at least one air hole formed in the movable mold to inject air into the cavity.

15. The roll-to-roll peeling device according to claim 1, wherein, The roll stripping device exposes the conductive core.

16. A vehicle including an electric motor having a hairpin manufactured using the roll-to-roll peeling apparatus according to claim 1.

17. An electric vehicle including a motor having a hair clip manufactured using the roll-to-roll peeling apparatus according to claim 1.

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