A flat copper wire torsion force and trajectory simulation mechanism and method
By designing a mechanism to simulate the torsional force and trajectory of flat copper wire, and combining it with grating sensors and force sensors, a rapid and accurate simulation of the torsional deformation of the stator of a flat wire motor was achieved. This solves the problems of long time consumption and high cost in existing technologies and provides accurate equipment debugging guidance.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- NEVEM INTELLIGENT TECHNOLOGY (SHANGHAI) CO LTD
- Filing Date
- 2026-03-02
- Publication Date
- 2026-06-19
AI Technical Summary
In existing technologies, the torsional deformation debugging process of flat wire motor stators is time-consuming and costly. Computer simulations cannot accurately quantify the physical properties of copper wires, resulting in large deviations between simulation results and actual conditions, and thus failing to effectively guide equipment debugging.
A mechanism for simulating the torsional force and trajectory of a flat copper wire was designed, including a copper wire clamping unit, an X-axis moving unit, a Y-axis following unit, a display unit, and a curve drawing unit. It integrates a force sensor and a magnetic grating displacement display device, simulates the deformation of the copper wire through actual torsion, and records the deformation force and displacement in real time with the help of a grating sensor.
It enables rapid and accurate simulation of torsional force and displacement changes, reduces debugging cycle and cost, provides a testing environment consistent with reality, guides equipment design, and provides initial data support.
Smart Images
Figure CN122247135A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of flat wire motor assembly equipment technology, and in particular to a mechanism and method for simulating the torsional force and trajectory of flat copper wire. Background Technology
[0002] Flat wire motors typically consist of a stator, rotor, and reducer, with the stator being one of the core components. The stator is the stationary part of the motor, usually composed of coils wound with copper wire, and is fixed in place within the motor housing. Its main function is to generate a magnetic field, driving the rotor to rotate and thus completing the motor's operation.
[0003] Torsional deformation at the welded ends of flat wire motors is a critical process in manufacturing. However, due to the complex plastic deformation involved and the variations in the size, resilience, and hardness of the flat copper wire, the resulting deformation varies. Currently, the industry primarily uses actual torsion testing and computer-aided stress deformation simulation for debugging guidance, which has the following two shortcomings: 1: The actual torsion process requires a very long cycle, and the process can only be carried out after the preceding processes have produced a complete product. Moreover, the debugging process requires repeated corrections and consumes dozens of stators to achieve the desired result. Both the time and material costs are very high. 2. Computer simulation cannot fully quantify the physical properties of copper wire, resulting in a large deviation between the simulated deformation process and the actual process, thus failing to provide true guidance for equipment debugging. Summary of the Invention
[0004] To solve the above-mentioned technical problems, this invention proposes a mechanism for simulating the torsional force and trajectory of a flat copper wire. The technical solution of this invention is implemented as follows: The first aspect of this invention discloses a mechanism for simulating the torsional force and trajectory of a flat copper wire, the mechanism comprising a copper wire clamping unit, an X-axis moving unit, a Y-axis following unit, a display unit, and a curve drawing unit; The display unit integrates a force sensor display device and a magnetic grating displacement display device; The copper wire clamping unit is configured to clamp the copper wire and apply a bending torque to the copper wire; The copper wire clamping unit includes a fixed part and a movable part; The fixing part is used to fix one end of the copper wire; The moving part is disposed on the Y-axis follower unit; The Y-axis follower unit is slidably mounted on the X-axis moving unit; The X-axis moving unit is connected to a torque transmission unit for applying torque on its outer side. The X-axis movement unit is equipped with an X-axis grating sensing unit; The Y-axis follower unit is equipped with a Y-axis grating sensing unit; The X-axis grating sensing unit and the Y-axis grating sensing unit are communicatively connected to the magnetic grating displacement display device; The curve drawing unit is connected to the moving part; The torque transmission unit is equipped with a force sensor for detecting torque.
[0005] Furthermore, both the moving part and the fixing part are provided with a wire clamp; The wire clamp includes an adjusting nut and a wire clamping unit disposed in a nut groove; The lower end of the adjusting nut is fixed to the pressure wire unit; Both the fixed part and the moving part are provided with movable copper wire stop blocks; A locking block is provided below the copper wire stop block; The locking mechanism is located within the sliding groove.
[0006] Furthermore, the curve drawing unit includes a curve drawing pen and a clamping arm; the curve drawing pen is fixed to the end of the clamping arm; The first end of the clamping arm is connected to the moving part.
[0007] Furthermore, the torque transmission unit includes a bending hand crank and a transmission shaft; One end of the drive shaft is connected to the Y-axis follower unit, and the other end is connected to the bending hand crank.
[0008] Furthermore, the X-axis rotation unit includes an X-axis guide rail; The Y-axis follower unit includes a Y-axis guide rail; The movable part is slidably fixed on the Y-axis guide rail.
[0009] The second aspect of this invention discloses a method for simulating the torsional force and trajectory of a flat copper wire, using the flat copper wire torsional force and trajectory simulation mechanism disclosed in the first aspect of this invention. The method includes the following steps: One end of the copper wire to be tested is fixed to the fixed part, and the other end is fixed to the moving part; The torque transmission unit drives the Y-axis follower unit located on the X-axis rotating unit to move along the X-axis; The moving part fixed on the Y-axis follower unit moves along the X-axis, thereby causing the copper wire to deform in the X-axis and Y-axis directions; The curve drawing unit, which is fixedly connected to the moving part, draws the displacement trajectory of the copper wire. At the same time, the Y-axis grating sensing unit and the X-axis grating sensing unit transmit the displacement of the copper wire in the X-axis direction and the movement in the Y-axis direction to the magnetic grating displacement display device. The force sensor transmits the collected pressure information to the force sensor display device.
[0010] Furthermore, the method also includes the following steps: When the specifications of the copper wire to be tested change, the width of the copper wire groove in the moving part and the fixed part can be adjusted by adjusting the position of the locking block in the sliding groove. Then, by adjusting the position of the nut in the nut groove, the position of the wire pressing unit can be adjusted; Finally, insert the copper wire with the changed specifications into the moving part and the fixing part, and fix the copper wire with the wire clamp.
[0011] The advantages of this invention are as follows: 1. The structure is simple and requires no program debugging. By simply clamping the copper wire and rotating it manually, the actual copper wire torsion condition can be simulated, and the accurate torsional force and displacement changes can be obtained. 2. High reusability: Only the positions of the two copper wire stop blocks in the fixed and moving parts need to be adjusted, and the position of the tightening nut on the wire clamp needs to be adjusted to test the torsion of copper wires with different wire widths and thicknesses. Through the sliding groove + locking block, the width of the copper wire slot can be adjusted according to actual needs to accommodate copper wires of different widths without the need to manufacture new parts. Attached Figure Description
[0012] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only one embodiment of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0013] Identical parts are indicated by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, while the terms "bottom surface," "top surface," "inner," and "outer" refer to directions toward or away from the geometric center of a specific part, respectively.
[0014] Figure 1 This is a schematic diagram of the structure of an embodiment of the present invention; Figure 2 This is a schematic diagram of the structure from another perspective of an embodiment of the present invention; Figure 3 A schematic diagram of the X-axis rotation unit and the Y-axis follower unit; Figure 4 This is a schematic diagram showing the position of the clamping elbow. Figure 5 This is a diagram showing the positional relationship between the wire clamp and the locking block; Figure 6 A schematic diagram of the structure of the copper wire blocking block; Figure 7 This is a structural diagram of the locking block and the sliding groove; Figure 8 This is a schematic diagram of the state of the copper wire after it has been deformed under stress.
[0015] In the above figures, the figure numbers indicate the following: 1. Force sensor display device; 2. Magnetic Grating Displacement Display Device 3. X-axis guide rail; 4. Y-axis guide rail; 5. Fixing part; 6. Mobile Department; 7. X-axis grating sensing unit; 8. Y-axis grating sensing unit; 9. Force sensor; 10. Pressing elbow clamp; 11. Adjusting nut; 12. Copper wire can block blocks; 13. Locking block; 14. Sliding groove; 15. Bending the hand-cranked handwheel; 16. Curve drawing pen. Detailed Implementation
[0016] The technical solutions of the present invention will now be clearly and completely described with reference to the embodiments and accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0017] Unless otherwise defined, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains; the terminology used in the detailed description is for the purpose of describing particular embodiments only and is not intended to limit the invention; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.
[0018] In the description of specific embodiments of the present invention, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of the present invention, "multiple" means two or more, unless otherwise explicitly defined.
[0019] In this invention, the reference to "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the invention. The appearance of this phrase in various places in the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described in this invention can be combined with other embodiments.
[0020] In the description of the embodiments of this invention, the term "and / or" is merely a description of the relationship between associated objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, in this invention, the character " / " generally indicates that the preceding and following associated objects have an "or" relationship.
[0021] The embodiments of the present invention will be described in more detail below through examples. It should be noted that the embodiments of the present invention are not limited to these examples.
[0022] In one specific embodiment, such as Figures 1-7 As shown, a mechanism for simulating the torsional force and trajectory of a flat copper wire includes a copper wire clamping unit, an X-axis moving unit, a Y-axis following unit, a display unit, and a curve drawing unit. The display unit integrates a force sensor display device 1 and a magnetic grating displacement display device 2; The copper wire clamping unit is configured to clamp the copper wire and apply a bending torque to the copper wire; The copper wire clamping unit includes a fixed part 5 and a movable part 6; The fixing part 5 is used to fix one end of the copper wire; The moving part 6 is mounted on the Y-axis follower unit; The Y-axis follower unit can be slidably mounted on the X-axis moving unit; The outside of the X-axis moving unit is connected to a torque transmission unit for applying torque. The X-axis movement unit is equipped with an X-axis grating sensing unit 7; The Y-axis follower unit is equipped with a Y-axis grating sensing unit 8; The X-axis grating sensing unit 7 and the Y-axis grating sensing unit 8 are communicatively connected to the magnetic grating displacement display device 2; The curve drawing unit is connected to the moving part 6; The torque transmission unit is equipped with a force sensor 9 for detecting torque.
[0023] In this embodiment, both the moving part 6 and the fixed part 5 are provided with a wire clamp 10; The wire clamp 10 includes an adjusting nut 11 and a wire clamping unit disposed in a nut groove; The lower end of the adjusting nut 11 is fixed to the wire pressing unit; Both the fixed part 5 and the movable part 6 are provided with movable copper wire stop blocks 12; A locking block 13 is provided below the copper wire blocking block 12; The locking mechanism is located within the sliding groove 14.
[0024] In this embodiment, the curve drawing unit includes a curve drawing pen 16 and a clamping arm; the curve drawing pen 16 is fixed to the end of the clamping arm. The first end of the clamping arm is connected to the moving part 6.
[0025] In this embodiment, the torque transmission unit includes a bending hand crank 15 and a transmission shaft; One end of the drive shaft is connected to the Y-axis follower unit, and the other end is connected to the bending hand crank 15.
[0026] In this embodiment, the X-axis rotation unit includes an X-axis guide rail 3; The Y-axis follower unit includes a Y-axis guide rail 4; The movable part 6 is slidably fixed on the Y-axis guide rail 4.
[0027] In this embodiment, the bending handwheel 15 is operated by the operator. The operator cranks the bending handwheel 15, which drives the Y-axis follower unit to move through the transmission shaft, thereby driving the movement of the moving part 6.
[0028] In this embodiment, the function of the wire clamping elbow 10 is to press the clamped flat wire tightly to prevent it from shifting vertically during movement. At the same time, the adjusting nut 11 on the wire clamping elbow 10 is used to adjust the position of the wire clamping unit, thereby cooperating with the adjustable copper wire stop block 12 below to fix copper wires of different specifications.
[0029] The specific operation process of this embodiment is as follows: First, fix one end of the copper wire to be tested on the fixing part 5 and the other end on the moving part 6. Adjust the position of the copper wire stop block 12 to ensure that the copper wire is completely fixed. Then, adjust the position of the wire pressing unit by adjusting the nut 11 to ensure that the wire pressing elbow 10 of the moving part 6 and the fixing part 5 fixes the copper wire.
[0030] The twisting and bending handwheel 15 drives the Y-axis follower unit located on the X-axis rotating unit to move along the X-axis guide rail 3; The moving part 6, which is fixed on the Y-axis follower unit, moves along the X-axis guide rail 3, thereby causing the copper wire to deform in the X-axis and Y-axis directions. A drawing paper is placed below the curve drawing pen 16, which is fixedly connected to the moving part 6. When the moving part 6 moves, the curve drawing pen 16 draws the displacement trajectory of the copper wire. The Y-axis grating sensing unit 8 and the X-axis grating sensing unit 7 transmit the displacement of the copper wire in the X-axis direction and the movement in the Y-axis direction to the magnetic grating displacement display device 2. The force sensor 9 transmits the collected pressure information to the force sensor display device 1. The twisted flat wire is as follows: Figure 8 As shown.
[0031] When the specifications of the copper wire to be tested change, the width of the copper wire groove in the moving part 6 and the fixed part 5 is adjusted by adjusting the position of the locking block 13 in the sliding groove 14. Then, by adjusting the position of the nut 11 in the nut groove, the position of the wire pressing unit can be adjusted; Finally, the copper wire with the modified specifications is inserted into the moving part 6 and the fixing part 5, and the copper wire is fixed by the wire clamp 10. Subsequent testing procedures are the same.
[0032] This embodiment, through the actual torsion of copper wire, combined with the grating displacement sensor and pressure sensor 9, can record the deformation force and deformation of the copper wire in real time throughout the entire deformation process. This provides a test environment that is completely consistent with reality for the design of the torsion head device, thereby accurately guiding the early design of the device and providing initial data support for the electrical program.
[0033] It should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. A flat copper wire torsion force and trajectory simulation mechanism, characterized by, The system includes a copper wire clamping unit, an X-axis moving unit, a Y-axis following unit, a display unit, and a curve drawing unit. The display unit integrates a force sensor display device and a magnetic grating displacement display device. The copper wire clamping unit is configured to clamp a copper wire and apply a bending torque to the wire. The copper wire clamping unit includes a fixing part and a moving part. The fixing part is used to fix one end of the copper wire. The moving part is disposed on the Y-axis following unit. The Y-axis following unit is slidably disposed on the X-axis moving unit. A torque transmission unit for applying torque is connected to the outside of the X-axis moving unit. The X-axis moving unit is provided with an X-axis grating sensing unit. The Y-axis following unit is provided with a Y-axis grating sensing unit. The X-axis grating sensing unit and the Y-axis grating sensing unit are communicatively connected to the magnetic grating displacement display device. The curve drawing unit is connected to the moving part. A force sensor for detecting torque is disposed on the torque transmission unit.
2. The flat copper wire torsion force and trajectory simulation mechanism according to claim 1, characterized in that, Both the moving part and the fixed part are provided with a wire pressing elbow clamp; the wire pressing elbow clamp includes an adjusting nut and a wire pressing unit disposed in a nut groove; the lower end of the adjusting nut is fixed to the wire pressing unit; both the fixed part and the moving part are provided with a movable copper wire stop block; a locking block is disposed below the copper wire stop block; the locking block is disposed in a sliding groove.
3. The flat copper wire torsional force and trajectory simulation mechanism according to claim 1, characterized in that, The curve drawing unit includes a curve drawing pen and a clamping arm; the curve drawing pen is fixed to the end of the clamping arm; the beginning of the clamping arm is connected to the moving part.
4. The flat copper wire torsional force and trajectory simulation mechanism according to claim 1, characterized in that, The torque transmission unit includes a bending handwheel and a transmission shaft; one end of the transmission shaft is connected to the Y-axis follower unit, and the other end is connected to the bending handwheel.
5. The flat copper wire torsional force and trajectory simulation mechanism according to claim 1, characterized in that, The X-axis rotation unit includes an X-axis guide rail; the Y-axis follower unit includes a Y-axis guide rail; and the moving part is slidably fixed on the Y-axis guide rail.
6. A method for simulating the torsional force and trajectory of a flat copper wire, using the flat copper wire torsional force and trajectory simulation mechanism as described in any one of claims 1-5, characterized in that, The method includes the following steps: fixing one end of the copper wire to be tested to a fixed part and the other end to a movable part; driving the Y-axis follower unit located on the X-axis rotation unit to move along the X-axis through the torque transmission unit; the movable part fixed on the Y-axis follower unit moves along the X-axis, thereby causing the copper wire to deform in the X-axis and Y-axis directions; the curve drawing unit fixedly connected to the movable part draws the displacement trajectory of the copper wire, while the Y-axis grating sensing unit and the X-axis grating sensing unit transmit the displacement of the copper wire in the X-axis direction and the movement in the Y-axis direction to the magnetic grating displacement display device, and the force sensor transmits the collected pressure information to the force sensor display device.
7. The method according to claim 6, characterized in that, The process also includes the following steps: when the specifications of the copper wire to be tested change, the width of the copper wire groove in the moving part and the fixed part is adjusted by adjusting the position of the locking block in the sliding groove; then the position of the wire pressing unit is adjusted by adjusting the position of the nut in the nut groove; finally, the copper wire with the changed specifications is placed into the moving part and the fixed part, and the copper wire is fixed by the wire pressing elbow clamp.