Flat wire stator hairpin forming equipment

Abstract

The invention provides flat wire stator hairpin forming equipment. The equipment comprises a rack, a hairpin fixing unit and a supporting leg forming unit, wherein the hairpin fixing unit and the supporting leg forming unit are integrally installed on the rack. The card issuing fixing unit comprises a clamping actuator A and a driving mechanism A matched with the clamping actuator A; a pair of clamping actuators A is arranged; each clamping actuator A is independently provided with a driving mechanism A used for driving the corresponding clamping actuator A to move freely in the Y direction and the Z direction. The supporting leg forming unit comprises a clamping actuator B and a driving mechanism B matched with the clamping actuator B; a pair of clamping actuators B is arranged; each clamping actuator B is independently provided with a driving mechanism B used for driving the corresponding clamping actuator B to move freely in the X direction, the Y direction and the Z direction. Compatible production of products of various specifications by one device is achieved, and the universality and production efficiency of the device can be effectively improved.

Description

Technical Field

[0001] This invention relates to the field of flat wire processing and manufacturing technology, specifically to a flat wire stator hairpin forming equipment. Background Technology

[0002] Stator hairpin 3D outward forming technology is a core precision plastic forming process in the manufacturing of stators for hairpin motors. Its main task is to shape the ends of the straight copper wires (called "hairpin legs"), which are randomly distributed after being inserted into the stator core slots, into end windings with a predetermined layered structure and spatial geometry through precise three-dimensional spatial positioning, twisting, unfolding, and bending. The core objective of this process is to achieve a transformation from "disorder" to "order," providing a precisely positioned, consistently spaced, and regularly shaped end structure for subsequent welding processes, thereby ensuring the reliability, consistency, and good heat dissipation performance of the motor winding electrical connections.

[0003] Currently, the industry widely uses stamping forming technology to achieve 3D outward forming of hair clips. This technology relies on pre-machined precision molds with specific cavities (punch and die), driven by a hydraulic or servo press, to perform integral or step-by-step stamping bending of the hair clip ends. Stamping processes offer advantages such as high forming speed, high production cycle, and good consistency in forming single-specification products, making them suitable for mass production. However, the molds relied upon by this technology are specialized; each set of molds is only suitable for specific product models. When different specifications of hair clips need to be produced, the corresponding molds must be changed, resulting in time-consuming changeover processes, increased production costs, and limited equipment production flexibility. Summary of the Invention

[0004] In order to solve the technical problems existing in the background art, the present invention proposes a flat wire stator hairpin forming device.

[0005] This invention proposes a flat wire stator hairpin forming device, comprising: a frame and a hairpin fixing unit and a leg forming unit integrated and mounted on the frame, wherein: The card fixing unit includes a clamping actuator A and a drive mechanism A that is matched with the clamping actuator A; there is a pair of clamping actuators A, which are arranged side by side in the X-axis direction; each clamping actuator A is independently configured with a corresponding drive mechanism A, which is configured to independently drive the corresponding clamping actuator A to move in the Y-axis direction and the Z-axis direction. The outrigger forming unit includes a clamping actuator B and a drive mechanism B that is matched with the clamping actuator B. There is a pair of clamping actuators B, which are arranged side by side in the X-axis direction, with one clamping actuator B located below one clamping actuator A and the other clamping actuator B located below another clamping actuator A. Each clamping actuator B is independently equipped with a corresponding drive mechanism B, which is configured to independently drive the corresponding clamping actuator B to move in the X-axis, Y-axis and Z-axis directions.

[0006] Preferably, the frame includes a lower frame and an upper frame disposed above and supported by the lower frame; the lower frame has a through opening corresponding to the lower part of the upper frame; the drive mechanism A in the card fixing unit is mounted on the upper frame, and its pair of clamping actuators A are disposed below the through opening; the drive mechanism B in the leg forming unit is mounted on the lower frame, and its pair of clamping actuators B are respectively disposed below the pair of clamping actuators A.

[0007] Preferably, the lower shelf includes a lower base plate and lower support legs supporting the lower base plate, with a through opening in the center of the lower base plate; the upper shelf includes an upper base plate and upper support legs supporting the upper base plate, with the upper base plate located above the through opening and the upper support legs fixed to the outside of the through opening.

[0008] Preferably, the drive mechanism A includes: The first Y-axis drive component is used to drive the clamping actuator A to move horizontally along the Y-axis direction; The first Z-axis drive component is used to drive the clamping actuator A to move vertically along the Z-axis direction.

[0009] Preferably, each drive mechanism A is equipped with a corresponding carrier A; the carrier A is mounted on the frame via a first Z-axis guide rail that is vertically arranged along the Z-axis direction; The first Z-axis drive component is fixedly mounted on the frame and connected to the carrier A, and is used to drive the carrier A to move linearly along the first Z-axis guide rail. The first Y-axis drive component is fixedly installed on the carrier A and connected to the corresponding clamping actuator A to drive the clamping actuator A (1) to move horizontally along the Y-axis direction.

[0010] Preferably, the first Z-axis drive component is a servo electric cylinder, which is fixed on the frame along the Z-axis direction, and its top end is fixedly connected to the carrier A.

[0011] Preferably, the first Y-axis drive component is a servo module and is fixed on the carrier A along the Y-axis direction; the clamping actuator A is fixedly installed on the slide of the first Y-axis drive component.

[0012] Preferably, the drive mechanism B includes: The X-axis drive component is used to drive the clamping actuator B to move horizontally along the X-axis direction. The second Y-axis drive component is used to drive the clamping actuator B to move horizontally along the Y-axis direction; The second Z-axis drive component is used to drive the clamping actuator B to move vertically along the Z-axis direction.

[0013] Preferably, each drive mechanism B is equipped with a corresponding carrier B and a carrier C that is slidably assembled with the carrier B; The second Z-axis drive component is fixedly mounted on the frame and connected to the carrier B to drive the carrier B to move vertically in the Z-axis direction. The X-axis drive component is fixedly mounted on the frame and connected to the carrier C via a connector that can move in the Z-axis direction, so as to drive the carrier C to move horizontally along the X-axis direction on the carrier B; The second Y-axis drive component is fixedly mounted on the carrier C and connected to the corresponding clamping actuator B to drive the connected clamping actuator B to move horizontally along the Y-axis direction.

[0014] Preferably, the X-axis drive component is connected to the carrier C via a Z-axis movable connector, and the second Z-axis drive component is fixedly connected to the carrier B; or, the X-axis drive component is fixedly connected to the carrier C, and the second Z-axis drive component is connected to the carrier B via a Z-axis fixed and X-axis movable connecting mechanism.

[0015] Preferably, the second Z-axis drive component includes a servo electric cylinder, which is fixed on the frame along the Z-axis direction, and its ejector end is fixedly connected to the carrier B.

[0016] Preferably, the X-axis drive component is a servo electric cylinder, which is fixed on the frame along the X-axis direction, and its ejector end is fixedly connected to the connector.

[0017] Preferably, the second Y-axis drive component is a servo module and is fixed on the carrier C along the Y-axis direction; the clamping actuator B is fixedly installed on the slide of the second Y-axis drive component.

[0018] This invention employs two independently driven clamping actuators A and B, which respectively achieve free displacement adjustment in the Y and Z directions and the X, Y, Z directions through a multi-axis drive mechanism. This not only enables precise control of clamping position and force, but also allows for flexible adaptation to hair clips of different heights and specifications. As a result, a single device can produce a variety of products with compatible specifications, effectively improving the versatility and production efficiency of the equipment. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of a flat wire stator hairpin forming device proposed in this invention; Figure 2This is a demonstration diagram showing the transformation of the hair clip from 2D to 3D. Figure 3 This is a schematic diagram of the structure of the hairpin fixing unit in the flat wire stator hairpin forming equipment proposed in this invention; Figure 4 This is a schematic diagram of the support leg forming unit in a flat wire stator hairpin forming device proposed in this invention. Detailed Implementation

[0020] Reference Figure 1-2 The present invention proposes a flat wire stator hairpin forming device, which includes: a frame and a hairpin fixing unit and a leg forming unit integrated and installed on the frame.

[0021] The frame 8 includes a lower frame 81 and an upper frame 82 disposed above and supported by the lower frame 81. The lower frame 81 has a through opening to accommodate the clamping component of the card-fixing unit. Specifically, the lower frame 81 consists of a lower base plate 811 and a lower support leg 812 supporting the lower base plate 811, with the through opening located in the center of the lower base plate 811. The upper frame 82 consists of an upper base plate 821 and an upper support leg 822 supporting the upper base plate 821. The upper base plate 821 is located above the through opening, while the upper support leg 822 is fixed to the lower base plate 811 outside the through opening.

[0022] The hair clip fixing unit is installed on the upper shelf 82, and its main function is to clamp and position the top part of the hair clip. The unit includes two sets of clamping actuators A1 arranged in parallel in the X-axis direction, and a drive mechanism A independently configured for each clamping actuator A1. The drive mechanism A is configured to independently drive the corresponding clamping actuator A to move in the Y-axis and Z-axis directions.

[0023] The leg forming unit is mounted on the lower frame 81. Its main function is to clamp the end (leg) of the hair clip and perform three-dimensional forming motion. This unit includes two sets of clamping actuators B4, which are arranged side-by-side in the X-axis direction, positioned directly below the two upper clamping actuators A1. Each clamping actuator B4 is also independently equipped with a drive mechanism B, configured to independently drive the corresponding clamping actuator B4 to move in the X, Y, and Z axes.

[0024] In a further embodiment, the structure of the hairpin fixing unit is designed as follows: Reference Figure 3The drive mechanism A includes a first Y-axis drive component 2 for driving the clamping actuator A1 to move horizontally along the Y-axis direction and a first Z-axis drive component 3 for driving the clamping actuator A1 to move vertically along the Z-axis direction. Each drive mechanism A is equipped with a carrier A9. The carrier A9 is mounted on the upper base plate 821 of the upper frame 82 via a set of first Z-guide rails arranged vertically along the Z-axis direction (not labeled in the figure).

[0025] The first Z-axis drive component 3 is fixedly mounted on the upper frame 82 and connected to the carrier A9, used to drive the carrier A9 and all components thereon to move vertically along the first Z-axis guide rail. Specifically, the first Z-axis drive component 3 is a servo electric cylinder, the cylinder body of which is fixed to the frame 8 along the Z-axis, and its top end is fixedly connected to the carrier A9.

[0026] The first Y-axis drive component 2 is fixedly mounted on the carrier A9 and connected to the corresponding clamping actuator A1, used to drive the clamping actuator A1 to move horizontally along the Y-axis direction. Specifically: the first Y-axis drive component 2 is a servo module, the base of which is fixed on the carrier A9 along the Y-axis direction, while the clamping actuator A1 is fixedly mounted on the slide of the servo module.

[0027] During operation, through the coordinated action of the first Y-axis drive component 2 and the first Z-axis drive component 3, each clamping actuator A1 can independently and precisely adjust its position in the YZ plane, thus accommodating the straight segments of hairpin tops of different heights. The clamping actuator A1 preferably adopts a servo gripper or a cylinder gripper to achieve flexible and adjustable clamping force on the hairpin.

[0028] In a further embodiment, the structural design of the leg forming unit is as follows: Reference Figure 4 The drive mechanism B includes an X-axis drive component 5 for driving the clamping actuator B4 to move horizontally along the X-axis, a second Y-axis drive component 6 for driving the clamping actuator B4 to move horizontally along the Y-axis, and a second Z-axis drive component 7 for driving the clamping actuator B4 to move vertically along the Z-axis. Each drive mechanism B is equipped with a carrier B (not labeled in the figure) and a carrier C (not labeled in the figure) that is slidably assembled with the carrier B. The carrier B is located below the lower base plate 811 of the frame 8.

[0029] The second Z-axis drive component 7 is fixedly mounted on the lower frame 81 of the frame 8 and connected to the carrier B. It is used to drive the entire carrier B and its components, such as the carrier C, to move vertically along the Z-axis. Specifically, the second Z-axis drive component 7 is a servo electric cylinder, with its cylinder body fixed along the Z-axis and its ejector end fixedly connected to the carrier B.

[0030] X-axis drive component 5 is used to drive the carrier C to move horizontally along the X-axis direction. Its specific connection relationship can adopt one of the following two preferred embodiments: Method 1: The X-axis drive component 5 is fixedly mounted on the frame 8, and its output end is connected to the carrier C via a connector 10 that can move along the Z-axis. The second Z-axis drive component 7 is fixedly connected to the carrier B. In this structure, when the X-axis drive component 5 drives the carrier C to move in the X-axis, the connector 10 can accommodate the independent movement of the carrier B in the Z-axis. Specifically: The X-axis drive component 5 is a servo electric cylinder, which is fixed on the frame 8 along the X-axis, and its ejector end is fixedly connected to the connector 10. The second Z-axis drive component 7 includes a servo electric cylinder, which is fixed on the frame 8 along the Z-axis, and its ejector end is fixedly connected to the carrier B.

[0031] Method 2: The X-axis drive component 5 is fixedly connected to the carrier C, while the second Z-axis drive component 7 is connected to the carrier B via a connection mechanism (not shown in the diagram) that is fixed in the Z-direction and movable in the X-direction. This structure also achieves motion decoupling between the X-axis drive and the Z-axis drive.

[0032] The second Y-axis drive component 6 is fixedly mounted on the carrier C and connected to the corresponding clamping actuator B4, used to drive the clamping actuator B4 to move horizontally along the Y-axis. Specifically, the second Y-axis drive component 6 is a servo module, and the clamping actuator B4 is fixedly mounted on its slide. The clamping actuator B4 is also preferably a servo gripper or a cylinder gripper.

[0033] During operation, the two clamping actuators A1 of the hairpin fixing unit, driven by their respective drive mechanisms A, move to the predetermined layer height Z-axis and front-to-back position Y-axis to clamp and fix the straight section at the top of the hairpin. Subsequently, the two clamping actuators B4 of the leg forming unit, driven by their respective drive mechanisms B, according to process requirements, drive the clamped hairpin end legs to complete precise outward turning, twisting, and other forming actions through the three-dimensional coordinated movement of the X-axis drive component 5, the second Y-axis drive component 6, and the second Z-axis drive component 7.

[0034] This invention separates the hair clip fixing unit and the leg forming unit in space using an upper and lower double-layer structure, and by equipping each clamping actuator with an independent multi-axis drive system, it can be compatible with the 3D outward forming of hair clips of various specifications.

[0035] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A flat wire stator hairpin forming device, characterized in that, include: The frame (8) and the hairpin fixing unit and the leg forming unit integrated and mounted on the frame (8), wherein: The hairpin fixing unit includes a clamping actuator A (1) and a drive mechanism A that is matched with the clamping actuator A (1); there is a pair of clamping actuators A (1), which are arranged side by side in the X-axis direction; each clamping actuator A (1) is independently configured with a corresponding drive mechanism A, which is configured to independently drive the corresponding clamping actuator A (1) to move in the Y-axis direction and the Z-axis direction; The outrigger forming unit includes a clamping actuator B (4) and a drive mechanism B that is matched with the clamping actuator B (4). There is a pair of clamping actuators B (4), which are arranged side by side in the X-axis direction. One clamping actuator B (4) is located below one clamping actuator A (1), and the other clamping actuator B (4) is located below the other clamping actuator A (1). Each clamping actuator B (4) is independently configured with a corresponding drive mechanism B, which is configured to independently drive the corresponding clamping actuator B (4) to move in the X-axis direction, Y-axis direction and Z-axis direction.

2. The flat wire stator hairpin forming equipment according to claim 1, characterized in that, The frame (8) includes a lower frame (81) and an upper frame (82) which is located above the lower frame (81) and supported by the lower frame (81); the lower frame (81) has a through opening below the upper frame (82); the drive mechanism A in the card fixing unit is installed on the upper frame (82), and its pair of clamping actuators A (1) are located below the through opening; the drive mechanism B in the leg forming unit is installed on the lower frame (81), and its pair of clamping actuators B (4) are respectively located below the pair of clamping actuators A (1).

3. The flat wire stator hairpin forming equipment according to claim 2, characterized in that, The lower shelf (81) includes a lower base plate (811) and a lower support leg (812) supporting the lower base plate (811). A through opening is provided in the center of the lower base plate (811). The upper shelf (82) includes an upper base plate (821) and an upper support leg (822) supporting the upper base plate (821). The upper base plate (821) is located above the through opening, and the upper support leg (822) is fixed to the outside of the through opening.

4. The flat wire stator hairpin forming equipment according to claim 1, characterized in that, Drive mechanism A includes: The first Y-axis drive component (2) is used to drive the clamping actuator A (1) to move horizontally along the Y-axis direction; The first Z-axis drive component (3) is used to drive the clamping actuator A (1) to move vertically along the Z-axis direction.

5. The flat wire stator hairpin forming equipment according to claim 4, characterized in that, Each drive mechanism A is equipped with a corresponding carrier A (9); the carrier A (9) is mounted on the frame (8) via a first Z-axis guide rail that is vertically set along the Z-axis direction; The first Z-axis drive component (3) is fixedly installed on the frame (8) and connected to the carrier A (9) to drive the carrier A (9) to move linearly along the first Z-axis guide rail; The first Y-axis drive component (2) is fixedly installed on the carrier A (9) and connected to the corresponding clamping actuator A (1) to drive the clamping actuator A (1) to move horizontally along the Y-axis direction.

6. The flat wire stator hairpin forming equipment according to claim 5, characterized in that, The first Z-axis drive component (3) adopts a servo electric cylinder, which is fixed on the frame (8) along the Z-axis direction, and its top end is fixedly connected to the carrier A (9); Preferably, the first Y-axis drive component (2) adopts a servo module and is fixed on the carrier A (9) along the Y-axis direction; the clamping actuator A (1) is fixedly installed on the slide of the first Y-axis drive component (2).

7. The flat wire stator hairpin forming equipment according to claim 1, characterized in that, Drive mechanism B includes: X-axis drive component (5) is used to drive clamping actuator B (4) to move horizontally along the X-axis direction; The second Y-axis drive component (6) is used to drive the clamping actuator B (4) to move horizontally along the Y-axis direction; The second Z-axis drive component (7) is used to drive the clamping actuator B (4) to move vertically along the Z-axis direction.

8. The flat wire stator hairpin forming equipment according to claim 7, characterized in that, Each drive mechanism B is equipped with a corresponding carrier B and a carrier C that is slidably assembled with the carrier B; The second Z-axis drive component (7) is fixedly installed on the frame (8) and connected to the carrier B to drive the carrier B to move vertically in the Z-axis direction; The X-axis drive component (5) is fixedly mounted on the frame (8) and connected to the carrier C via a connector (10) that can move in the Z-axis direction, so as to drive the carrier C to move horizontally in the X-axis direction on the carrier B; The second Y-axis drive component (6) is fixedly installed on the carrier C and connected to the corresponding clamping actuator B (4) to drive the connected clamping actuator B (4) to move horizontally along the Y-axis direction.

9. The flat wire stator hairpin forming equipment according to claim 8, characterized in that, The X-axis drive component (5) is connected to the carrier C via a Z-axis movable connector (10), and the second Z-axis drive component (7) is fixedly connected to the carrier B; or, the X-axis drive component (5) is fixedly connected to the carrier C, and the second Z-axis drive component (7) is connected to the carrier B via a Z-axis fixed and X-axis movable connecting mechanism. Preferably, the second Y-axis drive component (6) is a servo module and is fixed on the carrier C along the Y-axis direction; the clamping actuator B (4) is fixedly installed on the slide of the second Y-axis drive component (6).

10. The flat wire stator hairpin forming equipment according to claim 9, characterized in that, The second Z-axis drive component (7) includes a servo electric cylinder, which is fixed on the frame (8) along the Z-axis direction, and its ejector end is fixedly connected to the carrier B; Preferably, the X-axis drive component (5) is a servo electric cylinder, which is fixed on the frame (8) along the X-axis direction, and its top end is fixedly connected to the connector (10).

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