Support mechanism and pressing device for pressing a hairpin winding and a stator core

Abstract

The present application relates to a kind of hairpin winding and stator core press-fit support mechanism and press-fit device, including support frame with paper lifting plate and paper seat on paper lifting plate.Paper seat is provided with stop finger and line slot, for passing through tray jacking support stator core.Top line component includes multiple top line columns and servo drive, and top line column is threaded in line slot.In press-in stroke, top line column is in line slot with winding end abutment, and based on pressure feedback with winding synchronous downshift.By the active axial abutment of top line column and the shielding cooperation of paper seat, the stress modal of winding is optimized to steady-state support, effectively suppresses the buckling instability of winding and avoids the hooking and extrusion of insulating paper, while ensuring the neatness of winding end, significantly improves the press-fit efficiency and quality.

Description

Technical Field

[0001] This invention relates to the field of flat wire motor assembly technology, specifically to a support mechanism and pressing device for pressing hairpin windings and stator cores. Background Technology

[0002] As new energy vehicle drive motors continue to evolve towards higher power density, higher integration, and higher efficiency, hairpin windings made of flat copper wire have become the mainstream technology choice in the industry. Existing hairpin windings come in different configurations, such as X-pin, I-pin, or U-pin, and all configurations consist of multiple layers of flat copper wire. The axial length of each layer of flat wire is stepped at the pressing end. During actual assembly, the pre-formed and braided hairpin windings, arranged in a ring array, are pressed axially into the stator core slots pre-insulated with insulating paper using precision pressing equipment to complete the initial stator assembly.

[0003] For example, Chinese invention patent CN118611367A discloses a new energy stator carding wire assembly equipment. This equipment sets a carding tray on the bracket and opens multiple wire-passing grooves on the carding tray. When the carding wire drives the insulating paper to move axially under the action of the pressing unit, the carding tray forms a top support on the lower end face of the insulating paper, thereby preventing the insulating paper from turning outward or being damaged.

[0004] However, this solution has significant drawbacks when dealing with hairpin windings with non-flush ends. The main issue is that the end of the flat wire is axially suspended during its entry into and passage through the wire slot. This is a typical long cantilever structure with single-end pressure. Under this structure, when the flat wire overcomes severe frictional resistance as it descends through the iron core slot, the flat wire with a large length-to-diameter ratio is prone to axial buckling instability and end deflection. Small axial deflections can be rapidly amplified under high-voltage conditions, causing interference between the flat wire end and the edge of the insulating paper. This can lead to wrinkling of the insulating paper and a decrease in insulation performance, or even deformation of the winding end or tearing of the insulating paper, resulting in stator failure. Summary of the Invention

[0005] The purpose of this invention is to provide a support mechanism for pressing hairpin windings and stator cores, in order to solve the technical problems in the prior art where, during the overall pressing stroke of the hairpin winding, a single arm is suspended due to force at one end, which easily leads to radial deflection at the end of the stroke, causing damage and wrinkling to the insulating paper; the purpose of this invention is also to provide a pressing device using this support mechanism.

[0006] The technical solution of the support mechanism for pressing hairpin windings and stator cores according to the present invention is as follows: A support mechanism for pressing hairpin windings and stator cores includes: The support frame is used to provide support force to the stator core when the hairpin winding is pressed into the stator core; Paper holder, set on support frame, has multiple wire inlet slots for axial alignment with the wire slots of stator core, and a stop finger with a top-facing plane is formed between two adjacent wire inlet slots. Also includes: Top line assembly, mounted on the support frame, includes: The top wire holder is located directly below the paper cover holder; Several top wire posts are set on the top wire seat, each top wire post corresponds to each of the aforementioned wire inlet slots, and the top of the top wire post is provided with abutting surface that is adapted to and abuts the end of each flat wire of the hairpin winding. The driving component, in transmission cooperation with the top wire seat, drives each top wire post to move up and down; Each of the top wire posts is driven by the driving component to be inserted into the corresponding inlet slot. During the pressing of the hairpin winding, the upper end face of the top wire post abuts against the end of the hairpin winding in the inlet slot. The driving component is connected to the pressure head driving source signal of the external pressing equipment so that after the top wire post abuts against the hairpin winding, it drives the top wire post to move down synchronously with the hairpin winding, so as to form an axial abutment support to the end of the hairpin winding through the top wire post.

[0007] Furthermore, the top surface of the top post is divided into multiple segments along the radial direction, and each segment constitutes the abutment surface.

[0008] Furthermore, the top of the top wire column is provided with multiple steps distributed radially along the stator core. The height of the multiple steps decreases sequentially outward along the radial direction of the stator core, and each step surface of the multiple steps constitutes the abutment surface.

[0009] Furthermore, the top post has a plate-like structure, with guide slopes extending outward from top to bottom on both sides of its upper end.

[0010] Furthermore, the top wire assembly also includes a pressure sensor mounted on the top wire seat, and the drive unit adjusts the support force for the downward movement of the top wire post based on the feedback signal from the pressure sensor.

[0011] Furthermore, the support frame includes a base frame, on which a paper-protecting lifting plate is slidably mounted along the axial direction. The paper-protecting seat is fixed on the paper-protecting lifting plate. The base frame is also provided with a lifting cylinder for driving the paper-protecting lifting plate to move up and down. The paper-protecting lifting plate is provided with a through hole for the top wire column to pass through. The support frame is arranged below the conveyor line and directly below the pressing equipment. The upper surface of the paper-protecting lifting plate is used to push against the iron core tray on the conveyor line to push the iron core tray upward away from the conveyor line. The paper-protecting seat is used to push against the stator iron core inside the iron core tray to push the stator iron core upward away from the iron core tray.

[0012] Furthermore, the support frame also includes a press-fit support assembly disposed on the base frame. The press-fit support assembly includes a support slider that is horizontally slidably mounted on the base, and a horizontal push cylinder that drives the support slider to move. When the paper protector lifting plate pushes the paper protector seat into place upwards, the support slider moves between the paper protector lifting plate and the base frame.

[0013] Furthermore, there are two or more support sliders, which are evenly distributed at intervals along the circumference of the protective paper lifting plate.

[0014] Furthermore, the support sliders and lifting cylinders are staggered around the paper guard plate.

[0015] Furthermore, the base frame includes an assembly base plate and a mounting plate that is guided and mounted below the assembly base plate. The top wire seat is fixed on the mounting plate. The driving component is a servo electric cylinder connected between the assembly base plate and the mounting plate. A guide frame for connecting with the mounting plate is provided above the assembly base plate. The servo electric cylinder is fixed at the lower end of the assembly base plate, and the output end of the servo electric cylinder passes through the assembly base plate and is fixedly connected to the guide frame.

[0016] The technical solution of the press-fitting device of the present invention is as follows: The pressing device includes a pressing head arranged above the conveyor line and a support mechanism arranged below the conveyor line, the support mechanism including: The support frame is used to provide support force to the stator core when the hairpin winding is pressed into the stator core; Paper holder, set on support frame, has multiple wire inlet slots for axial alignment with the wire slots of stator core, and a stop finger with a top-facing plane is formed between two adjacent wire inlet slots. Also includes: Top line assembly, mounted on the support frame, includes: The top wire holder is located directly below the paper cover holder; Several top wire posts are set on the top wire seat, each top wire post corresponds to each of the aforementioned wire inlet slots, and the top of the top wire post is provided with abutting surface that is adapted to and abuts the end of each flat wire of the hairpin winding. The driving component, in transmission cooperation with the top wire seat, drives each top wire post to move up and down; Each of the top wire posts is driven by the driving component to be inserted into the corresponding inlet slot. During the pressing of the hairpin winding, the upper end face of the top wire post abuts against the end of the hairpin winding in the inlet slot. The driving component is connected to the pressure head driving source signal of the external pressing equipment so that after the top wire post abuts against the hairpin winding, it drives the top wire post to move down synchronously with the hairpin winding, so as to form an axial abutment support to the end of the hairpin winding through the top wire post.

[0017] Furthermore, the top surface of the top post is divided into multiple segments along the radial direction, and each segment constitutes the abutment surface.

[0018] Furthermore, the top of the top wire column is provided with multiple steps distributed radially along the stator core. The height of the multiple steps decreases sequentially outward along the radial direction of the stator core, and each step surface of the multiple steps constitutes the abutment surface.

[0019] Furthermore, the top post has a plate-like structure, with guide slopes extending outward from top to bottom on both sides of its upper end.

[0020] Furthermore, the top wire assembly also includes a pressure sensor mounted on the top wire seat, and the drive unit adjusts the support force for the downward movement of the top wire post based on the feedback signal from the pressure sensor.

[0021] Furthermore, the support frame includes a base frame, on which a paper-protecting lifting plate is slidably mounted along the axial direction. The paper-protecting seat is fixed on the paper-protecting lifting plate. The base frame is also provided with a lifting cylinder for driving the paper-protecting lifting plate to move up and down. The paper-protecting lifting plate is provided with a through hole for the top wire column to pass through. The support frame is arranged below the conveyor line and directly below the pressing equipment. The upper surface of the paper-protecting lifting plate is used to push against the iron core tray on the conveyor line to push the iron core tray upward away from the conveyor line. The paper-protecting seat is used to push against the stator iron core inside the iron core tray to push the stator iron core upward away from the iron core tray.

[0022] Furthermore, the support frame also includes a press-fit support assembly disposed on the base frame. The press-fit support assembly includes a support slider that is horizontally slidably mounted on the base, and a horizontal push cylinder that drives the support slider to move. When the paper protector lifting plate pushes the paper protector seat into place upwards, the support slider moves between the paper protector lifting plate and the base frame.

[0023] Furthermore, there are two or more support sliders, which are evenly distributed at intervals along the circumference of the protective paper lifting plate.

[0024] Furthermore, the support sliders and lifting cylinders are staggered around the paper guard plate.

[0025] Furthermore, the base frame includes an assembly base plate and a mounting plate that is guided and mounted below the assembly base plate. The top wire seat is fixed on the mounting plate. The driving component is a servo electric cylinder connected between the assembly base plate and the mounting plate. A guide frame for connecting with the mounting plate is provided above the assembly base plate. The servo electric cylinder is fixed at the lower end of the assembly base plate, and the output end of the servo electric cylinder passes through the assembly base plate and is fixedly connected to the guide frame.

[0026] The beneficial effects of this application are as follows: Compared with the prior art, the hairpin winding and stator core pressing support mechanism involved in this invention, through the design of the paper holder and the top wire assembly, addresses the significant mechanical frictional resistance between the flat wire and the core slot during the pressing stroke. Furthermore, the flat wire ends are not evenly distributed. By controlling the top wire post to rise into the slot in advance through a driving component, the upper end of the top wire post abuts against the stator core as the flat wire ends downwards through it. This transforms the stress mode of the flat wire from a long cantilever structure with single-end pressure to a stable support structure with both ends constrained. During this process, the top wire post moves synchronously with the winding pressing down and provides continuous axial resisting force, effectively counteracting the instability torque caused by the pressing load. This ensures that the flat wire maintains a high-precision axial trajectory throughout its final formation range through the core, eliminating radial impact caused by the deflection of the flat wire ends.

[0027] Meanwhile, because the top post abuts against the end of the flat wire inside the inlet slot, it not only provides axial support for the flat wire, but also, through its cooperation with the side wall of the inlet slot, forces the end of the flat wire to be constrained within the inner diameter envelope of the insulating paper. This ensures that after the end of the flat wire leaves the iron core constraint, it is locked in the guide channel formed by the stop finger and the top post, so that the end of the flat wire and the edge of the insulating paper always maintain a safe gap of non-contact or a small squeezing contact force, eliminating the physical damage to the insulation system caused by the pressing pressure.

[0028] Furthermore, because the top post moves synchronously downward with the winding within the infeed slot and provides controlled axial damping, it effectively absorbs the impact caused by frictional fluctuations during the pressing stroke, transforming the flat wire's movement within the core from an unstable stick-slip state to a stable, uniform feed state. This controlled follow-up process not only reduces the instantaneous frictional load on the insulating paper but also utilizes the precise axial positioning reference of the top post to correct the ends of non-flush flat wires at the pressing endpoint, significantly improving the manufacturing precision and product yield of the stator assembly. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of a specific embodiment of the support mechanism for pressing the hairpin winding and stator core according to the present invention; Figure 2 for Figure 1 A schematic diagram showing the cooperation between the central support mechanism and the iron core tray; Figure 3 for Figure 1 A schematic diagram of the structure of the middle protective paper lifting plate and the protective paper base; Figure 4 for Figure 1 Schematic diagram of the structure of the top-mounted wire assembly; Figure 5 for Figure 4 A schematic diagram of the structure of the top-line column.

[0030] In the diagram: 11-Assembly base plate; 12-Paper protector lifting plate; 13-Mounting plate; 14-Support slider; 15-Lifting cylinder; 16-Horizontal push cylinder; 17-Guide shaft; 2-Paper protector seat; 21-Support inner step; 22-Wire inlet groove; 23-Block finger; 3-Top wire seat; 31-Top wire column; 311-Multi-stage step; 312-Top surface; 313-Guide slope; 32-Column; 33-Servo electric cylinder; 34-Lifting guide column; 35-Connecting plate; 4-Conveyor line; 5-Iron core tray. Detailed Implementation

[0031] The principles and spirit of the present invention will be explained in detail below with reference to several representative embodiments.

[0032] Specific embodiments of the support mechanism for pressing the hairpin winding and stator core of the present invention are as follows: Figures 1 to 5 As shown, this support mechanism is mainly used in the hairpin winding (such as hairpin, I-pin or X-pin winding) pressing station of the motor stator production line. It is arranged below the conveyor line 4 to provide rigid support for the stator core and stress-bearing components during the process of the external pressing equipment driving the stator winding to be axially pressed into the stator core.

[0033] The support mechanism mainly consists of three parts: a support frame, a paper protector assembly, and a top wire assembly nested inside the support frame. The support frame is responsible for the overall positioning, lifting, and bypass transfer of the pressing load; the paper protector assembly is responsible for establishing the docking interface between the stator core and the tooling and for statically limiting the insulating paper; the top wire assembly provides continuous axial feedback support force to the end of the flat wire through axial follow-up logic synchronized with the pressing head.

[0034] Specifically, the support frame is used to provide support force to the stator core when the hairpin winding is pressed into the stator core. It includes a base frame, which includes a fixed assembly plate 11. The assembly plate 11 is arranged horizontally and is rigidly connected to the foundation of the work station directly or through an intermediate component. The assembly plate 11 is provided with four guide shafts 17. Each guide shaft 17 is evenly distributed around the circumference of the assembly plate 11 and is guided and slidably assembled on the assembly plate 11, and can move up and down along the assembly plate 11.

[0035] The paper protector assembly includes a paper protector lifting plate 12 axially slidably mounted on a base frame. The four corners of the paper protector lifting plate 12 are connected to the aforementioned guide shafts 17. A driving component is provided between the mounting base plate 11 and the paper protector lifting plate 12, specifically two lifting cylinders 15 symmetrically distributed below the paper protector lifting plate 12. The cylinder body of the lifting cylinder 15 is fixed to the bottom side of the mounting base plate 11, extends axially upward through the mounting base plate 11, and is fixedly connected to the bottom side edge of the paper protector lifting plate 12. Through the synchronous action of the lifting cylinders 15, the paper protector lifting plate 12 is driven to smoothly rise and fall along the extension direction of the guide shafts 17, thereby causing the paper protector seat 2 above it to enter or exit the working position.

[0036] In order to protect the output shaft of the lifting cylinder 15 and the conveyor line 4 from the impact load generated during the pressing process, the support frame also includes a pressing support assembly set on the base frame. The pressing support assembly includes two or more support sliders 14 that are horizontally slidably mounted on the assembly base plate 11, and a horizontal push cylinder 16 that drives the support sliders 14 to move. There are two support sliders 14, which are symmetrically arranged around the circumference of the paper lifting plate 12.

[0037] The support slider 14 is mounted on the assembly base plate 11 via a guide rail. The support slider 14 and the lifting cylinder 15 are spatially staggered to maximize space utilization and ensure uniform support force. The height of the support slider 14 is adapted to the axial gap between the paper cover lifting plate 12 and the assembly base plate 11 when the paper cover lifting plate 12 is in the raised position. When the paper cover lifting plate 12 is pushed to a predetermined height by the lifting cylinder 15, the horizontal push cylinder 16 drives the support slider 14 to move horizontally into the gap between the paper cover lifting plate 12 and the assembly base plate 11. At this time, the bottom surface of the paper cover lifting plate 12 can be lowered to fit against the top surface of the support slider 14.

[0038] In subsequent pressing conditions, the huge axial pressure acting on the paper protector lifting plate 12 is no longer transmitted through the cylinder piston rod, but is transmitted through the paper protector lifting plate 12 and the support slider 14 to the rigid assembly base plate 11. Mechanical limiting is used instead of pneumatic support to avoid structural fatigue or instability of the lifting cylinder 15 due to instantaneous high pressure, thereby improving the service life and pressing accuracy of the equipment under high frequency and heavy load conditions.

[0039] The paper protector assembly also includes a paper protector base 2, which serves as the workpiece directly contacting the stator core and is positioned on the paper protector lifting plate 12. The top surface of the paper protector base 2 has a supporting inner step 21 for supporting the end face of the stator core. Multiple stop fingers 23 arranged in a circular array are provided on the outer circumferential surface of the supporting inner step 21. A wire inlet groove 22 is formed between adjacent stop fingers 23. The number and angular position of the wire inlet grooves 22 correspond one-to-one with and are coaxially aligned with the wire slots of the stator core. Furthermore, the top surface height of the supporting inner step 21 is higher than the top surface height of the stop fingers 23. The supporting inner step 21 is placed inside the stator core, allowing the paper protector base 2 to maintain stable contact with the bottom of the stator core, ensuring stable and accurate insertion of the copper wire.

[0040] During the pressing process, the insulating paper is prone to downward displacement due to friction. By pre-tightening the stop finger 23 and positioning the iron core with the inner support step 21, the downward movement of the insulating paper and the space for wrinkles are effectively blocked.

[0041] The top wire assembly is arranged on the base frame, including a top wire seat 3 located directly below the paper protector seat 2, and several top wire posts 31 vertically arranged on the upper surface of the top wire seat 3. The axis of the top wire seat 3 is consistent with the axis of the paper protector seat 2, and each top wire post 31 corresponds one-to-one with the wire inlet groove 22 on the paper protector seat 2. Correspondingly, the center position of the paper protector lifting plate 12 is provided with a vertically extending clearance hole. The top wire seat 3 is driven by a driving component, which can drive each top wire post 31 to pass upward through the clearance hole on the paper protector lifting plate 12 and insert into the corresponding wire inlet groove 22. The driving component is connected to the pressure head drive source signal of the external pressing equipment, so that after the top wire post 31 abuts against the hairpin winding, it drives the top wire post 31 to move downward synchronously with the hairpin winding, so as to form axial support to the end of the hairpin winding through the top wire post 31.

[0042] To accommodate the non-flush end characteristics of the X-pin hairpin winding, each top post 31 has a corresponding abutment surface 312 at its top end, which is adapted to abut the end of each flat wire of the hairpin winding. Specifically, the top end of the top post 31 has multiple steps 311 distributed radially along the stator core. The height of the multiple steps 311 decreases sequentially outward along the radial direction of the stator core, and each step surface of the multiple steps 311 constitutes the abutment surface 312. This stepped distribution structure forms a reverse adaptation abutment with the length distribution of the ends of the flat wires of each layer of the hairpin winding, ensuring that during the pressing stroke, whether it is a longer outer flat wire or a shorter inner short wire, a stable axial abutment can be formed with the corresponding abutment surface 312 at the predetermined forming node, eliminating axial buckling and radial sway caused by some flat wires being suspended during pressing.

[0043] The top wire post 31 has a plate-like structure to fit the narrow space of the wire inlet groove 22. The upper end of the top wire post 31 has two side walls in the thickness direction with guide slopes 313 that gradually extend outward from top to bottom. During the process of the top wire post 31 cutting into the wire inlet groove 22, the guide slopes 313 make the top end of the top wire post 31 narrow, which can automatically compensate for the accumulated error of the mechanism and guide the plate-like top wire post 31 to smoothly and without collision into the corresponding wire inlet groove 22.

[0044] To drive the top wire assembly, a mounting plate 13 is guided and mounted below the mounting base 11. The top wire seat 3 is fixed to the mounting plate 13 by a vertical column 32. The driving component is a servo electric cylinder 33 connected between the mounting base 11 and the mounting plate 13. Guide frames connected to the mounting plate 13 are provided on both sides of the mounting base 11. The servo electric cylinder 33 is fixed at the lower end of the mounting base 11, and the output end of the servo electric cylinder 33 passes through the mounting base 11 and is fixedly connected to the guide frame.

[0045] For the guide frame, two sets of guide sleeves are symmetrically arranged on opposite sides of the assembly base plate 11. Each set of guide sleeves includes two guide sleeves, and each guide sleeve has a lifting guide post 34 inserted vertically. The top of the two lifting guide posts 34 is connected to a connecting plate 35, and the bottom of the two lifting guide posts 34 is connected to a mounting plate 13. At the same time, the output shaft of the servo electric cylinder 33 is connected to the connecting plate 35. In this assembly configuration, the servo electric cylinder 33 drives the output shaft to push the connecting plate 35 upward. The connecting plate 35, through the lifting guide posts 34, synchronously drives the mounting plate 13 located below the assembly base plate 11. The mounting plate 13 then transmits the power upward through the assembly base plate 11 to the top wire seat 3 via the vertical column 32. This assembly relationship of bottom-driven, top-linked, and bottom-moving, utilizing the four-point guidance of the guide frame, greatly enhances the stability of the movement of the mounting plate 13, ensures the straightness of the sliding of the top wire post 31 in the wire inlet groove 22, and also allows the servo electric cylinder 33 to avoid the axial heavy-load path in the pressing center area.

[0046] In addition, the top wire assembly also includes a pressure sensor mounted on the top wire seat 3. The servo electric cylinder 33 adjusts the supporting force for the downward movement of the top wire post 31 based on the feedback signal from the pressure sensor.

[0047] Actual action process: This support mechanism is arranged below the conveyor line 4 and is located on the axis of the press head drive path of the external pressing equipment. The conveyor line 4 is equipped with a core tray 5, and the stator core is placed in the core tray 5. When the conveyor line 4 drives the core tray 5 to move to the center of the workstation, the support mechanism enters the start-up phase.

[0048] The lifting cylinder 15 receives a start signal and drives the paper-protecting lifting plate 12 located above the assembly base plate 11 to rise vertically along the axis. At this time, the paper-protecting seat 2 on the paper-protecting lifting plate 12 passes through the bottom center clearance hole of the iron core tray 5 and achieves positioning and pushing cooperation with the bottom surface of the stator iron core inside the iron core tray 5. As the paper-protecting lifting plate 12 continues to rise, the paper-protecting seat 2 pushes the stator iron core upward to disengage from the iron core tray 5. At the same time, the paper-protecting lifting plate 12 pushes the iron core tray 5 away from the conveyor line 4. Through the paper-protecting lifting plate 12 and the paper-protecting seat 2, the stator iron core and the iron core tray 5 are pushed upward away from the conveyor line 4, thereby pushing the stator iron core to the working height.

[0049] After the iron core tray 5 is lifted, the horizontal thrust cylinder 16 drives the symmetrically distributed support sliders 14 to move horizontally into the axial gap between the paper protector lifting plate 12 and the assembly base plate 11. As the support sliders 14 move into position, the bottom surface of the paper protector lifting plate 12 and the top surface of the support sliders 14 are physically attached. The support sliders 14 and the lifting cylinders 15 are staggered around the paper protector lifting plate 12. It transfers the huge axial impact force generated during the pressing stroke from the piston rod of the lifting cylinder 15, which relies on air pressure support, to the rigid metal transmission chain composed of the paper protector lifting plate 12, the support sliders 14, and the base of the assembly base plate 11.

[0050] Subsequently, the servo cylinder 33 is activated, and as the mounting plate 13 rises, the column 32 drives the top wire holder 3 and the top wire post 31 to move upwards. The top wire post 31 smoothly inserts into the corresponding inlet slot 22 via the guide ramp 313. Then, the external pressure head drives the winding downwards and presses it through the iron core, abutting against the multi-step 311 at the top of the top wire post 31. The pressure sensor on the top wire holder 3 senses the load in real time. Once the pressure reaches the preset threshold, the servo cylinder 33 drives the top wire post 31 to move downwards synchronously with the winding.

[0051] Without top wire support, the flat wire is in a "single-end pressure cantilever" state, making it prone to axial buckling when overcoming the enormous friction within the wire groove. The radial component of this bending force is the main power source for wrinkling the insulation paper. The top wire post 31, by abutting against the wire inlet groove 22, provides axial support feedback force to the flat wire. As the top wire post 31 moves downwards, the feedback force provided by the servo cylinder 33 maintains the force balance of the flat wire, resulting in a steady-state pressure mode with support at both ends. This also ensures that the flat wire is pressed down smoothly without causing radial displacement that could damage the insulation paper.

[0052] After the pressure head fully presses the windings into the core, the non-flush flat wires of each layer are physically leveled on the stepped surface of the top post 31. The pressure head then retracts. The horizontal push cylinder 16 retracts the support slider 14, and the lifting cylinder 15 lowers the paper protector lifting plate 12. As the paper protector seat 2 and the paper protector lifting plate 12 fall back, the stator core also falls back into the core tray 5. After the paper protector seat 2 completely detaches from the core tray 5, the core tray 5 and the pressed stator core return to the conveyor line 4 and flow to the next station.

[0053] In other embodiments, the top of the top post may also adopt a contoured arc surface with a preset curvature or an asymmetrical variable slope structure.

[0054] In other embodiments, the multi-level steps can also be configured as a step array with non-equal spacing or locally staggered heights, according to a specific winding arrangement rule.

[0055] In other embodiments, the pressure sensor may be replaced by a current feedback module or torque monitoring unit integrated inside the servo cylinder, so as to indirectly adjust the support feedback force when the top column moves down by monitoring the change in the output power of the drive source.

[0056] In other embodiments, the press-fit support assembly may also employ a rotary support ring or a wedge locking mechanism, which, by establishing a physical interference interface in the vertical direction, transfers the axial high pressure borne by the paper guard plate to the base.

[0057] In other embodiments, the number of support sliders may be set to three or four, and they may be distributed in a centrally symmetrical triangular or circumferential array.

[0058] An embodiment of the press-fitting device designed in this invention includes a press-fitting head arranged above the conveyor line and a support mechanism arranged below the conveyor line. The structure of the support mechanism is consistent with the structure of the various embodiments of the hairpin winding and stator core press-fitting support mechanism described above, and will not be described in detail.

[0059] Based on the above description in this specification, those skilled in the art will also understand that the following terms, such as "upper," "lower," "front," "rear," "left," "right," "width," "horizontal," "top," "bottom," "inner," and "outer," which indicate orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings of this specification. They are only for the purpose of facilitating the explanation of the present invention and simplifying the description, and do not explicitly or implicitly suggest that the device or element involved must have the specific orientation, or be constructed and operated in a specific orientation. Therefore, the above-mentioned orientation or positional relationship terms should not be understood or interpreted as limitations on the present invention.

[0060] In addition, in the description of this specification, "multiple" means at least two, such as two, three or more, etc., unless otherwise expressly and specifically defined.

Claims

1. A support mechanism for pressing a hairpin winding into a stator core, comprising: The support frame is used to provide support force to the stator core when the hairpin winding is pressed into the stator core; Paper holder, set on support frame, has multiple wire inlet slots for axial alignment with the wire slots of stator core, and a stop finger with a top-facing plane is formed between two adjacent wire inlet slots. Its characteristic is that it further includes: Top line assembly, mounted on the support frame, includes: The top wire holder is located directly below the paper cover holder; Several top wire posts are set on the top wire seat, each top wire post corresponds to each of the aforementioned wire inlet slots, and the top of the top wire post is provided with abutting surface that is adapted to and abuts the end of each flat wire of the hairpin winding. The driving component, in transmission cooperation with the top wire seat, drives each top wire post to move up and down; Each of the top wire posts is driven by the driving component to be inserted into the corresponding inlet slot. During the pressing of the hairpin winding, the upper end face of the top wire post abuts against the end of the hairpin winding in the inlet slot. The driving component is connected to the pressure head driving source signal of the external pressing equipment so that after the top wire post abuts against the hairpin winding, it drives the top wire post to move down synchronously with the hairpin winding, so as to form an axial abutment support to the end of the hairpin winding through the top wire post.

2. The support mechanism for pressing the hairpin winding and stator core according to claim 1, characterized in that, The top surface of the top post is divided into multiple segments along the radial direction, and each segment constitutes the top surface.

3. The support mechanism for pressing the hairpin winding and stator core according to claim 2, characterized in that, The top of the top post is provided with multiple steps distributed radially along the stator core. The height of the multiple steps decreases sequentially outward along the radial direction of the stator core, and each step surface of the multiple steps constitutes the top surface.

4. The support mechanism for pressing the hairpin winding and stator core according to claim 1, characterized in that, The top wire assembly also includes a pressure sensor mounted on the top wire seat, and the drive unit adjusts the support force for the downward movement of the top wire post based on the feedback signal from the pressure sensor.

5. The support mechanism for pressing the hairpin winding and stator core according to any one of claims 1-4, characterized in that, The support frame includes a base frame, on which a paper-protecting lifting plate is slidably mounted along the axial direction. The paper-protecting seat is fixed on the paper-protecting lifting plate. The base frame is also provided with a lifting cylinder for driving the paper-protecting lifting plate to move up and down. The paper-protecting lifting plate is provided with a through hole for the top wire column to pass through. The support frame is arranged below the conveyor line and directly below the pressing equipment. The upper surface of the paper-protecting lifting plate is used to push against the iron core tray on the conveyor line to push the iron core tray upward away from the conveyor line. The paper-protecting seat is used to push against the stator iron core inside the iron core tray to push the stator iron core upward away from the iron core tray.

6. The support mechanism for pressing the hairpin winding and stator core according to claim 5, characterized in that, The support frame also includes a press-fit support assembly mounted on the base frame. The press-fit support assembly includes a support slider that is horizontally slidably mounted on the base, and a horizontal push cylinder that drives the support slider to move. When the paper protector lifting plate pushes the paper protector seat into place, the support slider moves between the paper protector lifting plate and the base frame.

7. The support mechanism for pressing the hairpin winding and stator core according to claim 6, characterized in that, There are two or more support sliders, which are evenly distributed at intervals along the circumference of the protective paper lifting plate.

8. The support mechanism for pressing the hairpin winding and stator core according to claim 7, characterized in that, Supporting sliders and lifting cylinders are staggered around the paper guard plate.

9. The support mechanism for pressing the hairpin winding and stator core according to claim 5, characterized in that, The base frame includes an assembly base plate and a mounting plate that is guided and mounted below the assembly base plate. The top wire seat is fixed on the mounting plate. The driving component is a servo electric cylinder connected between the assembly base plate and the mounting plate. A guide frame for connecting with the mounting plate is provided above the assembly base plate. The servo electric cylinder is fixed at the lower end of the assembly base plate, and the output end of the servo electric cylinder passes through the assembly base plate and is fixedly connected to the guide frame.

10. A pressing device, comprising a pressing head disposed above a conveyor line and a support mechanism disposed below the conveyor line, characterized in that, The support mechanism is the hairpin winding and stator core press-fit support mechanism as described in any one of claims 1-9.

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