Shaping and positioning device and method for formed hard winding coil

Abstract

The invention provides a shaping and positioning device and method for a formed hard winding coil. The shaping and positioning device for the formed hard winding coil comprises a base, a traction assembly and a shaping assembly, the traction assembly and the shaping assembly are arranged on the base, the shaping assembly is higher than the traction assembly, the traction assembly comprises a linear mechanism, and a traction connecting block and a positioning piece are sequentially arranged at the movable end of the linear mechanism. The positioning piece and the multiple shaping assemblies are sequentially arranged in the stroke direction of the linear mechanism, each shaping assembly comprises a clamping mechanism, and the two movable ends of each clamping mechanism are each sequentially provided with a shaping connecting block and a shaping piece. The shaping and positioning method for the formed hard winding coil comprises the steps of coil grabbing, coil clamping, traction shaping, coil taking out and the like. According to the shaping and positioning device and method for the formed hard winding coil, the problem that it is difficult for a robot to accurately grab the hard winding coil is solved.

Description

Technical Field

[0001] This invention relates to the field of electric motors, and more specifically to a forming and positioning device and method for hard-wound coils. Background Technology

[0002] Hard windings are formed coils made of insulated flat wire or conductors. They have high strength. The insulated flat wire or conductor needs to be processed into a specific shape of coil before it can be embedded into the stator core slots of the motor. Typically, the electromagnetic wire is first wound into a shuttle-shaped coil, and then formed into a coil with a spatial shape. Because the coil is not a machined component and has lead ends, its shape and spatial posture can deviate, making it difficult for robots to accurately grasp it in automated production lines. The disadvantages include: poor precision (the coil's posture is unstable in a free state, resulting in low grasping and positioning accuracy and a tendency to jam); low efficiency (secondary positioning is time-consuming, and the success rate of grasping is greatly affected by the coil's posture); high risk of damage (unstable grasping and forced correction can easily scratch the coil insulation layer); and poor automation compatibility (it is difficult to achieve high-speed, seamless automated processes).

[0003] Therefore, considering adding a rapid positioning and shaping process for the coil after winding and before forming, the coil shape will be more precise and the position more accurate, enabling the robot to accurately grasp the coil and thus automate the coil manufacturing process. Summary of the Invention

[0004] To address the challenge of precise robotic grasping of hard-wound coils, this invention provides a shaping and positioning device and method for formed hard-wound coils.

[0005] A forming and positioning device for a hard-wound coil includes a base, a traction component and a forming component disposed on the base, the forming component being higher than the traction component, the traction component including a linear mechanism, the movable end of the linear mechanism being provided with a traction connecting block and a positioning element in sequence, the positioning element and a plurality of the forming components being arranged in sequence along the travel direction of the linear mechanism, the forming component including a clamping mechanism, the two movable ends of the clamping mechanism being provided with a forming connecting block and a forming element in sequence, the travel direction of the clamping mechanism intersecting the travel direction of the linear mechanism, the forming connecting block extending away from the traction component, and the forming elements being disposed on the side adjacent to the forming connecting block.

[0006] In a preferred embodiment of the forming and positioning device for hard-wound coils provided by the present invention, the bottom surface of the base is provided with the traction component, the top surface is provided with a plurality of the forming components, and a notch is provided for the traction connecting block and the positioning component to extend to the top surface.

[0007] In a preferred embodiment of the forming and positioning device for hard-wound coils provided by the present invention, the forming connecting block extends upward and inward, and the forming element is provided at the innermost position; the forming element is a guide wheel, which is vertically connected to the forming connecting block in the axial direction, has a buffer layer covering its edge, and extends beyond the edge of the forming connecting block. The upper end of the positioning element is higher than the upper side of the forming element.

[0008] In a preferred embodiment of the forming and positioning device for hard-wound coils provided by the present invention, a metering unit is further included, comprising a sensor support on the top surface of the base and a sensor disposed on its top; the sensor is vertically adjustable.

[0009] In a preferred embodiment of the forming hard winding coil shaping and positioning device provided by the present invention, the shaping component further includes an inner support unit, including an inner support seat disposed on the clamping mechanism or the base, and an inner support roller assembly disposed on the top of the inner support seat, the inner support roller assembly being located between the shaping connecting blocks.

[0010] In a preferred embodiment of the forming hard winding coil shaping and positioning device provided by the present invention, the top surface of the base is provided on both sides of the notch, and one or more external support units are provided along the travel direction of the linear mechanism, including two external support seats symmetrically arranged on both sides of the notch, and external support roller groups respectively arranged on their tops; a gap is provided between the two external support roller groups in the same external support unit for the positioning member to pass through.

[0011] In a preferred embodiment of the forming and positioning device for hard-wound coils provided by the present invention, both the outer support roller group and the inner support roller group include one or more rollers at the same height; all the rollers are at the same height.

[0012] A method for shaping and positioning a formed hard-wound coil, wherein the forming hard-wound coil shaping and positioning device is controlled by a production line control system, comprising: Step 1: In the in-situ state, the clamping mechanism opens, the linear mechanism retracts, and the positioning element is located close to the shaping component; Step 2: Control the robot or manually grasp the coil, place the nose of the coil onto the positioning component, and position the two sides of the coil between the shaping components; Step 3: Control the clamping mechanism to retract, so that the shaping part squeezes the coil, shapes the coil to the required size, and maintains the clamping state; Step 4: Control the linear mechanism to extend, drive the positioning component to move forward, pull the nose of the coil, and move the entire coil forward to the set position; Step 5: Control the clamping mechanism to open, and control the robot to remove the coil; Step 6: Control the linear mechanism to return to its original position.

[0013] In a preferred embodiment of the forming and positioning method for a hard-wound coil provided by the present invention, a sensor is provided above the base; in step 2, when the nose of the coil is fitted onto the positioning component, or when both sides of the coil are placed between the forming components, the sensor acquires a first signal; in step 6, when the coil is removed, the sensor acquires a second signal; both the first signal and the second signal are transmitted to the production line control system.

[0014] Compared with the prior art, the forming and positioning device and method for hard-wound coils provided by the present invention have the following beneficial effects: 1. The shaping and positioning device provided by the present invention uses the nose of the coil as a reference for positioning, which can shape the straight part of the coil, making the shape and position of the coil more accurate, making it easier for the robot to grasp the coil, so as to realize the automation of coil manufacturing.

[0015] 2. The shaping and positioning device provided by the present invention uses a buffered guide wheel to achieve the shaping action, generating rolling friction at the contact position to avoid damage to the coil insulation.

[0016] 3. The shaping and positioning device provided by this invention is equipped with multiple shaping components, which complete the shaping process through short-distance movement. This simplifies the structure of the traction component, improves equipment stability, and increases shaping efficiency. Furthermore, the multi-segment structure is suitable for coils of different lengths.

[0017] 4. In the shaping and positioning device provided by this invention, the traction component uses a positioning element to traction the nose of the coil, which facilitates positioning the noses of coil leads of different specifications to the same position. Furthermore, by replacing the positioning element, this device can be adapted to coils with different arc sizes.

[0018] 5. The shaping and positioning method provided by this invention enables rapid positioning and shaping of coils, and can integrate the positioning and shaping process into the existing production line process, making it easy to achieve high-speed, seamless automated production of formed hard-winding coils. Attached Figure Description

[0019] Figure 1 This is a three-dimensional view of a device for shaping and positioning rigid winding coils; Figure 2 It is a three-dimensional view of the traction component in the forming and positioning device for hard-wound coils; Figure 3 This is a three-dimensional view of the shaping component in the forming and positioning device for hard-wound coils; Figure 4 This is a three-dimensional view of the metering unit in the forming and positioning device for hard-wound coils; Figure 5This is a three-dimensional view of the outer support unit in the forming and positioning device for hard-wound coils.

[0020] The following components are labeled in the diagram: base 1, notch 11, traction assembly 2, linear mechanism 21, traction connecting block 22, positioning component 23, shaping assembly 3, clamping mechanism 31, shaping connecting block 32, shaping component 33, inner support seat 34, inner support roller group 35, metering unit 4, sensor support 41, sensor 42, outer support unit 5, outer support seat 51, outer support roller group 52. Detailed Implementation

[0021] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0022] Please also refer to Figures 1 to 5 These are perspective views of the forming and positioning device for hard-wound coils provided by the present invention, and perspective views of the traction component 2, the shaping component 3, the metering unit 4, and the external support unit 5 therein. The forming and positioning device for hard-wound coils includes a base 1, a traction component 2, a shaping component 3, a metering unit 4, and an external support unit 5.

[0023] The base 1 is a table structure with a long strip notch 11 on the left side of the top tabletop. Three shaping components 3 are arranged in sequence on the right side of the top of the tabletop. A traction component 2 is arranged on the right side of the bottom of the tabletop. The center lines of the notch 11, the shaping component 3, and the traction component 2 are aligned.

[0024] The traction assembly 2 includes a linear mechanism 21, a traction connecting block 22, and a positioning element 23. The linear mechanism 21 is a double-piston cylinder with its piston rod facing left, and the traction connecting block 22 is located at the left end of the piston rod. The traction connecting block 22 has an inverted T-shaped structure, and the top end is equipped with a positioning element 23, which is also an inverted T-shaped structure. The traction connecting block 22 passes through a notch 11, the length of which is greater than the stroke of the linear mechanism 21. When the linear mechanism 21 extends or retracts, the traction connecting block 22 is positioned within the notch 11 near the left or right end, respectively. The upper end of the positioning element 23 is a vertical rod with an oval cross-section, the longitudinal direction of which is the extension / retraction direction of the linear mechanism 21. Furthermore, by replacing the positioning element 23, this device can be adapted to coils with different arc sizes.

[0025] On both sides of the center of the notch 11, there are also external support units 5. The external support unit 5 includes an external support base 51 and an external support roller assembly 52. ​​The two external support bases 51 are symmetrically arranged on both sides of the notch 11, and on the top of the two external support bases 51, on the adjacent side, two external support roller assemblies 52 are symmetrically arranged. The external support roller assembly 52 includes two rollers at the same height. There is a gap between the two external support roller assemblies 52 for the rod at the upper end of the positioning member 23 to pass through.

[0026] The shaping assembly 3 includes a clamping mechanism 31, a shaping connecting block 32, and a shaping element 33. The clamping mechanism 31 is a clamping cylinder with both ends extending and retracting synchronously, and symmetrically equipped with shaping connecting blocks 32. The shaping connecting block 32 has an L-shaped structure, extending upwards and inwards, with a shaping element 33 located on its innermost lower part. The shaping element 33 is a guide wheel, its rotating shaft vertically mounted on the shaping connecting block 32. The outer wall of the shaping element 33 has a buffer layer, preferably made of a high-performance material with sufficient strength but a slightly soft texture that does not easily damage the insulation. The buffer layer of the shaping element 33 extends beyond the innermost part of the shaping connecting block 32 to prevent the coil from contacting the shaping connecting block 32.

[0027] The shaping assembly 3 also includes an inner support unit, comprising an inner support base 34 and an inner support roller assembly 35. Two inner support bases 34 are symmetrically positioned at both ends of the top of the cylinder of the clamping mechanism 31, with the inner support roller assembly 35 positioned between them. The inner support unit is located between the shaping connecting blocks 32, and the inner support roller assembly 35 is located below the shaping component 33. The inner support roller assembly 35 includes two rollers at the same height, and their height is consistent with that of the outer support roller assembly 52.

[0028] A measuring unit 4 is located at the top edge of the desktop, between the outer support unit 5 and the leftmost shaping component 3. The measuring unit 4 includes a sensor support 41 at the top of the desktop and a sensor 42 mounted on top of the sensor support 41. The sensor support 41 has a vertical strip-shaped through hole for mounting the sensor 42, allowing the height of the sensor 42 to be adjusted for accurate measurement.

[0029] In use, the forming hard-winding coil shaping and positioning device provided by this invention is controlled by an existing production line control system. The control flow of the forming hard-winding coil shaping and positioning device, i.e., the forming hard-winding coil shaping and positioning method, includes the following steps: Step 1: In the original position, the clamping mechanism 31 opens, the linear mechanism 21 retracts, and the positioning component 23 is located near the leftmost shaping component 3.

[0030] Step 2: Manually place the nose of the coil onto the rod at the upper end of the positioning component 23, and then lower the coil after positioning both sides between the two shaping components 33. At this time, the straight edge of the coil rests on the inner support roller group 35 of the three shaping components 3.

[0031] Step 3: Sensor 42 senses that the coil is in place and sends a signal to the production line control system, which controls the clamping mechanism 31 to retract, so that the shaping part 33 comes together and squeezes the two sides of the coil, shaping the coil to the required size and maintaining the clamping state.

[0032] Step 4: Subsequently, the linear mechanism 21 extends, driving the positioning member 23 to move forward and pass through the outer support roller group 52, pulling the nose of the coil and moving the entire coil forward to the set position. At this time, the straight edge of the coil near the nose rests on the outer support roller group 52, while the other end moves away from the rightmost inner support roller group 35. Through this pulling action, both sides of the coil fully contact the shaping members 33, ensuring that the coil is thoroughly shaped to the required size.

[0033] Step 5: Then, control the clamping mechanism 31 to open and release the coil. At this point, the shaping is complete, and the existing robot can be controlled by the production line control system to remove the coil.

[0034] Step 6: Finally, control the linear mechanism 21 to return to its original position. Sensor 42 detects that the coil has been removed and sends a signal to the production line control system to prepare for the subsequent processing.

[0035] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A shaping and positioning device for a hard-wound coil, characterized in that: The device includes a base, and a traction component and a shaping component disposed on the base. The shaping component is higher than the traction component. The traction component includes a linear mechanism. The movable end of the linear mechanism is provided with a traction connecting block and a positioning component in sequence. The positioning component and a plurality of the shaping components are arranged in sequence along the travel direction of the linear mechanism. The shaping component includes a clamping mechanism. The two movable ends of the clamping mechanism are respectively provided with a shaping connecting block and a shaping component in sequence. The travel direction of the clamping mechanism intersects with the travel direction of the linear mechanism. The shaping connecting block extends away from the traction component. The shaping components are respectively disposed on the side close to the shaping connecting block.

2. The forming and positioning device for hard-wound coils according to claim 1, characterized in that: The base has the traction component on its bottom surface and multiple shaping components on its top surface, with a notch for the traction connecting block and the positioning component to extend to the top surface.

3. The forming and positioning device for a hard-wound coil according to claim 1 or 2, characterized in that: The shaping connecting block extends upward and inward, and the shaping component is provided at the innermost position; the shaping component is a guide wheel, which is vertically connected to the shaping connecting block in the axial direction, and its edge is covered with a buffer layer and extends beyond the edge of the shaping connecting block.

4. The forming and positioning device for hard-wound coils according to claim 3, characterized in that: The upper end of the positioning member is higher than the upper side of the shaping member.

5. The forming and positioning device for a hard-wound coil according to claim 4, characterized in that: It also includes a metering unit, including a sensor support on the top surface of the base and a sensor located on top of it; the sensor is vertically adjustable.

6. The forming and positioning device for a hard-wound coil according to claim 4 or 5, characterized in that: The shaping assembly further includes an inner support unit, comprising an inner support seat disposed on the clamping mechanism or the base, and an inner support roller assembly disposed on the top of the inner support seat, the inner support roller assembly being located between the shaping connecting blocks.

7. The forming and positioning device for a hard-wound coil according to claim 6, characterized in that: The top surface of the base is provided on both sides of the notch, and one or more external support units are provided along the travel direction of the linear mechanism, including two external support seats symmetrically arranged on both sides of the notch, and external support roller groups respectively provided on their tops; there is a gap between the two external support roller groups in the same external support unit for the positioning member to pass through.

8. The forming and positioning device for a hard-wound coil according to claim 7, characterized in that: Both the outer support roller group and the inner support roller group include one or more rollers at the same height; all rollers are at the same height.

9. A method for shaping and positioning a hard-winding coil based on the shaping and positioning device of any one of claims 1 to 8, characterized in that, The forming and positioning device for the hard-wound coil is controlled by the production line control system, including: Step 1: In the in-situ state, the clamping mechanism opens, the linear mechanism retracts, and the positioning element is located close to the shaping component; Step 2: Control the robot or manually grasp the coil, place the nose of the coil onto the positioning component, and position the two sides of the coil between the shaping components; Step 3: Control the clamping mechanism to retract, so that the shaping part squeezes the coil, shapes the coil to the required size, and maintains the clamping state; Step 4: Control the linear mechanism to extend, drive the positioning component to move forward, pull the nose of the coil, and move the entire coil forward to the set position; Step 5: Control the clamping mechanism to open, and control the robot to remove the coil; Step 6: Control the linear mechanism to return to its original position.

10. The method for shaping and positioning a hard-wound coil according to claim 9, characterized in that: A sensor is provided above the base; in step 2, when the nose of the coil is fitted onto the positioning component, or when both sides of the coil are placed between the shaping component, the sensor acquires a first signal; in step 6, when the coil is removed, the sensor acquires a second signal; both the first signal and the second signal are transmitted to the production line control system.

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