A stator winding forming device and method for new energy vehicle flat wire motor production

Abstract

The present application relates to motor manufacturing technical field, disclose a kind of new energy automobile flat wire motor production stator winding forming equipment and method, new energy automobile flat wire motor production stator winding forming equipment includes pre-delivery line portion, paint removal portion, cutting portion, bending forming portion, 3D forming portion and automatic weaving winding portion in turn along material flow direction, the present application is realized from copper wire raw material to the winding of weaving completion, all processes are automatically completed by equipment, greatly improve production efficiency, and through magnetic suspension annular conveying line, realize the precise positioning and high-speed transmission in 3D forming process, combined with multi-station gradual forming, effectively control the rebound and distortion of flat wire when bending in three-dimensional space, and the design of one-use one-backup of pre-delivery line portion realizes no stop change material, the alternate clamping wire of cutting portion can adapt to copper wire section of different length, each forming station of 3D forming portion is all using servo drive, satisfy the production demand of multiple specifications flat wire motor.

Description

Technical Field

[0001] This invention relates to the field of motor manufacturing technology, specifically to a stator winding forming equipment and method for producing flat wire motors for new energy vehicles. Background Technology

[0002] With the booming development of the new energy vehicle industry, drive motors are rapidly evolving towards higher power density, higher efficiency, and miniaturization. Flat wire motors, due to their significant advantages such as high slot fill factor, good heat dissipation, and high torque density, have become the mainstream technology. The core manufacturing difficulty of flat wire motors lies in the forming and assembly of the stator windings. Flat copper wire differs from traditional round copper wire; it needs to be bent multiple times in space to form a complex "hairpin" shape and embed it into the stator core slots. Currently, the manufacturing processes commonly used in the industry have many defects.

[0003] I. Existing equipment has a low degree of automation, mostly consisting of single-machine operation or semi-automatic production lines. Material transfer between processes relies on manual labor or simple mechanisms, resulting in slow production cycle, high labor costs, and poor product quality consistency.

[0004] Second, the forming accuracy of flat wire is difficult to guarantee. Because flat wire has a rectangular cross-section, it is very easy to cause cross-sectional distortion, inconsistent springback and insulation layer damage during bending and torsion, which directly affects the motor's withstand voltage performance and electrical performance.

[0005] Third, the existing equipment lacks flexibility. For flat wire products of different models, wire diameters and spans, equipment changeover and adjustment are complicated and may even require the replacement of a large number of molds, making it difficult to adapt to the production needs of multiple varieties and small batches.

[0006] Fourth, the existing production lines are loosely laid out, occupy a large area, and lack an effective online detection and quality feedback mechanism, resulting in a high scrap rate. Summary of the Invention

[0007] The purpose of this invention is to provide a highly integrated and intelligent flat wire motor stator winding forming equipment and method to solve the problems of low efficiency, poor forming accuracy and insufficient automation of existing production line equipment mentioned in the background art.

[0008] To achieve the above objectives, the present invention adopts the following technical solution:

[0009] A stator winding forming equipment for producing flat wire motors for new energy vehicles includes a pre-feeding section, a paint removal section, a cutting section, a bending and forming section, a 3D forming section, and an automatic braiding winding section.

[0010] The pre-feeding section is equipped with at least two sets of switchable pre-feeding mechanisms. Each pre-feeding mechanism is provided with a wire winding power mechanism, a buffer mechanism one, a wire feeding drive mechanism, a buffer mechanism two, and a straightening mechanism in sequence along the copper wire conveying direction. These mechanisms are used to straighten the copper wire until it meets the straightness requirements of the process before outputting it.

[0011] The paint removal section is equipped with a laser paint removal module, which includes a support mechanism, a paint removal transverse movement mechanism, multiple circumferentially distributed paint removal laser heads, a laser head focal length adjustment mechanism, and a dust suction cavity mechanism corresponding to the paint removal laser heads, for laser ablation and removal of the insulating varnish layer at a specified location on the copper wire.

[0012] The cutting section is equipped with a linear motor driven wire feeding module and an alternating clamping module. The linear motor driven wire feeding module includes a right wire feeding motor and a left wire feeding motor. The alternating clamping module includes a right jaw and a left jaw, which are used to realize the continuous feeding of copper wire and cutting at a preset length.

[0013] The bending and forming section is equipped with a material picking and punching mechanism, a transfer mechanism, a wire pushing mechanism, a wire feeding mechanism, a bending and forming mechanism, and a material unloading mechanism. The transfer mechanism is used to divert the cut copper wire to at least two processing channels. The wire feeding mechanism cooperates with the bending and forming mechanism to complete the planar bending and forming of the copper wire.

[0014] The 3D forming section is equipped with at least two independently operating annular magnetic levitation conveyor lines. Each annular magnetic levitation conveyor line is sequentially equipped with a feeding station, a height adjustment station, a roof bottle cap forming station, a staggered bending forming station, a splitting forming arc station, a forming pressure resistance testing station, and a unloading station, which are used to perform three-dimensional spatial forming of copper wire after planar bending.

[0015] The automatic braiding winding section is equipped with robot insertion and picking modules that match the number of the annular magnetic levitation conveyor lines. Each robot insertion and picking module includes a robot, a material picking fixture, a guide plate intervention mechanism, an inner support spool mechanism, and a pressing mechanism, which are used to insert the three-dimensionally formed copper wires into the spools in sequence to complete the winding braiding.

[0016] Preferably, the number of pre-feeding mechanisms in the pre-feeding section is two, arranged on both sides with one in use and one as a backup; the first buffer mechanism and the second buffer mechanism are floating guide wheel group structures, and the straightening mechanism includes multiple sets of straightening rollers arranged in an alternating manner.

[0017] Preferably, the number of the plurality of paint removal laser heads is four, which are circumferentially distributed around the copper wire at 90-degree intervals; the paint removal transverse movement mechanism is used to drive the paint removal laser head to move along the copper wire axis to the position where paint needs to be removed; the laser head focal length adjustment mechanism is used to adjust the focal point of the paint removal laser head to the paint layer surface; the dust suction chamber mechanism is disposed on one side of the copper wire and the dust suction port is directly opposite the scanning area of ​​the paint removal laser head.

[0018] Preferably, the right and left grippers alternately clamp and release under the coordination of the control system. The right wire feeding motor drives the right gripper to reciprocate, and the left wire feeding motor drives the left gripper to reciprocate. The right and left wire feeding motors drive each other alternately to achieve continuous relay feeding of copper wire.

[0019] Preferably, the transfer mechanism is a linear motor module with dual channels, used to laterally transfer the cut copper wire from the cutting station and alternately distribute it to the two processing channels. The wire pushing mechanism is used to push the copper wire into the wire feeding mechanism. The wire feeding mechanism and the bending and forming mechanism work together synchronously to complete the bending and forming of the copper wire. The bending and forming mechanism bends the copper wire into a preset two-dimensional shape by rotational bending. The wire pushing mechanism, wire feeding mechanism, bending and forming mechanism and unloading mechanism are arranged on both the left and right sides in the bending and forming part.

[0020] Preferably, there are two annular magnetic levitation conveyor lines, namely a left magnetic levitation and a right magnetic levitation, arranged in a mirror image layout; the loading station, height adjustment station, roof bottle cap forming station, staggered bending forming station, split forming arc station, post-forming pressure resistance testing station, and unloading station are arranged in a mirror image layout on the left and right magnetic levitations, and the running direction of the left magnetic levitation is opposite to that of the right magnetic levitation.

[0021] Preferably, the robot insertion module consists of two parts, namely a left winding section and a right winding section, which are respectively set at the unloading stations of the left magnetic levitation and the right magnetic levitation. The guide plate intervention mechanism is a retractable guide plate structure, which is used to expand the guide width of the spool slot entrance when the copper wire is inserted into the spool. The inner support spool mechanism is a cylindrical structure adapted to the internal shape of the stator core, and its circumferential surface is provided with slots corresponding to the stator slots. The pressing mechanism is used to apply an insertion force in a set direction to the copper wire and press the copper wire into the corresponding slot of the inner support spool mechanism.

[0022] A method for forming stator windings for flat wire motor production includes the following steps:

[0023] Step 1, the pre-feeding step, uses one of at least two switchable pre-feeding mechanisms to supply copper wire to the equipment, so that the copper wire passes through the unwinding of the wire winding power mechanism, the tension buffering of the buffer mechanism one, the active wire feeding of the wire feeding drive mechanism, the tension buffering of the buffer mechanism two again, and the multi-stage straightening process of the straightening mechanism to obtain flat copper wire that meets the straightness requirements.

[0024] Step 2, laser paint removal step: The copper wire is supported and positioned by the support mechanism. The paint removal transverse movement mechanism moves multiple circumferentially distributed paint removal laser heads to the position of the copper wire where paint needs to be removed. After the laser head focal length adjustment mechanism adjusts the focal position, the laser ablation is started to remove the insulating varnish layer. At the same time, the dust collection chamber mechanism collects dust from the paint removal area.

[0025] Step 3, continuous wire feeding and cutting step: the copper wire is clamped alternately by the right and left jaws, and the copper wire is continuously fed in a relay manner by the right and left wire feeding motors. After being fed to the preset length, the copper wire is cut by the material picking and punching mechanism.

[0026] Step four, planar bending and forming step: the cut copper wire is diverted to any one of at least two processing channels by the transfer mechanism, the copper wire is pushed into the wire feeding mechanism by the wire pushing mechanism, the wire feeding mechanism and the bending and forming mechanism cooperate to bend the copper wire into a preset two-dimensional shape in the plane, and the formed wire is output by the unloading mechanism.

[0027] Step 5, the three-dimensional forming step, places the copper wire after planar bending on the loading station of any one of at least two independently operating circular magnetic levitation conveyor lines, so that the copper wire passes through the height adjustment station, the roof bottle cap forming station, the staggered bending forming station, and the splitting forming arc station in sequence to be bent and formed in three-dimensional space. After being tested for pressure resistance at the forming pressure resistance testing station, it is output from the unloading station.

[0028] Step six, automatic weaving step: The robot, in conjunction with the material handling fixture, takes the three-dimensional shaped copper wire that has passed the pressure resistance test from the unloading station. After being guided by the guide plate intervention mechanism, it is inserted into the corresponding slots of the inner support spool mechanism in sequence. The pressing mechanism presses the copper wire into place, completing the automatic weaving of the winding.

[0029] Preferably, in step one, there are two sets of pre-feeding mechanisms arranged on both the left and right sides. When the copper wire of the working pre-feeding mechanism is exhausted, the control system automatically switches to another pre-feeding mechanism to continue feeding wire, realizing material change without stopping the machine. The straightening mechanism includes multiple sets of straightening rollers arranged in an alternating manner. The pressing amount of the straightening rollers is automatically adjusted according to the diameter specification of the current copper wire.

[0030] Preferably, in step two, there are four paint removal laser heads, which are circumferentially distributed around the copper wire at 90-degree intervals. During paint removal, the four paint removal laser heads move synchronously along the axial direction of the copper wire under the drive of the paint removal transverse movement mechanism, forming a continuous scanning band around the copper wire to complete the paint layer ablation. The dust suction chamber mechanism is set on one side of the copper wire and the dust suction port is directly facing the scanning area of ​​the paint removal laser head. During the paint removal process, continuous suction is performed. After the paint removal is completed, the quality of the copper wire surface in the paint removal area is judged by visual inspection.

[0031] The technical effects and advantages of this invention are as follows:

[0032] 1. This invention realizes the full automation of the stator winding forming process of flat wire motor. From copper wire raw materials to the braided winding, all processes are completed automatically by the equipment without human intervention, which greatly improves production efficiency and reduces labor costs.

[0033] 2. This invention achieves precise positioning and high-speed transmission in the 3D forming process through a magnetically levitated ring conveyor line. Combined with a multi-station step-by-step forming strategy, it effectively controls the springback and distortion of the flat wire when bending in three-dimensional space, and significantly improves the dimensional accuracy and consistency of the winding forming.

[0034] 3. This invention has extremely high system flexibility. The one-use-one-standby design of the pre-feeding section enables material change without stopping the machine. The alternating clamping and feeding of the cutting section can adapt to copper wire segments of different lengths. Each forming station of the 3D forming section adopts servo drive, and the stamping stroke and angle can be adjusted by the program to achieve rapid shape change and meet the production needs of flat wire motors of various specifications.

[0035] 4. This invention integrates an online withstand voltage testing station, which can immediately inspect the integrity of the copper wire insulation layer after three-dimensional molding, realize closed-loop quality control, effectively prevent defective products from flowing into subsequent processes, and improve the yield of the final product.

[0036] 5. This invention adopts a dual-channel parallel and dual-side mirror layout design, which doubles the production capacity in a limited space. The equipment occupies a small area and has a high output rate per unit area. Attached Figure Description

[0037] Figure 1 This is a schematic diagram of the overall layout of a stator winding forming equipment for the production of flat wire motors for new energy vehicles, as proposed in this invention.

[0038] Figure 2 This is a three-dimensional structural diagram of the pre-feeding line portion in this invention;

[0039] Figure 3 This is a three-dimensional structural diagram of the paint-removing part in this invention;

[0040] Figure 4 This is a schematic diagram of the cut-off portion structure in this invention;

[0041] Figure 5 This is a schematic diagram of the bending and forming part in this invention;

[0042] Figure 6 This is a schematic diagram of the 3D molding part in this invention;

[0043] Figure 7 This is a schematic diagram of the automatic braided winding section in this invention.

[0044] In the picture:

[0045] 1. Pre-feeding section; 11. Wire winding power mechanism; 12. Buffer mechanism one; 13. Wire feeding drive mechanism; 14. Buffer mechanism two; 15. Straightening mechanism;

[0046] 2. Paint removal section; 21. Support mechanism; 22. Paint removal transverse movement mechanism; 23. Paint removal laser head; 24. Laser head focus adjustment mechanism; 25. Dust suction chamber mechanism;

[0047] 3. Cutting section; 31. Right wire feed motor; 32. Right gripper; 33. Left wire feed motor; 34. Left gripper;

[0048] 4. Bending and forming section; 41. Material handling and punching mechanism; 42. Transfer mechanism; 43. Wire pushing mechanism; 44. Wire feeding mechanism; 45. Bending and forming mechanism; 46. Unloading mechanism;

[0049] 5.3D molding section; 5L, left-side magnetic levitation; 5R, right-side magnetic levitation; 51, loading station; 52, height adjustment station; 53, roof cap molding station; 54, staggered bending molding station; 55, splitting arc molding station; 56, post-molding pressure resistance testing station; 57, unloading station.

[0050] 6. Automatic braided winding section; 6L, left winding section; 6R, right winding section; 61, robot; 62, material handling fixture; 63, guide plate intervention mechanism; 64, internal support spool mechanism; 65, pressing mechanism. Detailed Implementation

[0051] The subject matter described herein will now be discussed with reference to exemplary embodiments. It should be understood that these embodiments are discussed only to enable those skilled in the art to better understand and implement the subject matter described herein, and changes may be made to the function and arrangement of the elements discussed without departing from the scope of this specification. Various processes or components may be omitted, substituted, or added as needed in the examples. Furthermore, features described in some examples may be combined in other examples.

[0052] Example 1

[0053] This invention provides, for example Figures 1 to 7 As shown, a stator winding forming equipment for the production of flat wire motors for new energy vehicles includes a pre-feeding section, a paint removal section, a cutting section, a bending and forming section, a 3D forming section, and an automatic braiding winding section. The whole machine adopts a modular assembly structure, and the functional parts are connected through standard interfaces, which facilitates transportation, installation and maintenance.

[0054] In traditional flat wire motor production workshops, the aforementioned processes are typically completed by independent single machines. For example, paint removal might use a chemical paint stripping tank or mechanical paint scraper, cutting might use a punch press, bending might use another CNC pipe bending machine, and 3D molding might use multiple hydraulic presses in conjunction with manual mold changing. Material transfer between machines relies on manual trolleys or AGV carts, and manual loading and unloading are required before and after each process. Taking a production line with an annual output of 100,000 stators as an example, the traditional segmented layout of the equipment typically occupies more than 300 square meters, with a large amount of work-in-process inventory between processes (approximately 200-300 pieces). Material handling time accounts for about 40% of the entire production cycle, and at least 6-8 operators are required per shift.

[0055] In contrast, this invention integrates all functional modules into one device, with the entire machine occupying only about 80-100 square meters, saving more than 60% of factory space. More importantly, the various processes are directly connected by robotic arms or conveyor lines. The copper wire completes the entire processing from raw material to formed winding inside the equipment, without the need for manual or external logistics intervention. It operates in a continuous production mode, and the entire process from copper wire raw material input to finished winding output takes only about 2-3 minutes per piece (compared to about 15-20 minutes per piece for traditional segmented systems). The work-in-process inventory is reduced to less than 10 pieces, and the entire line only requires one inspector to operate.

[0056] After the equipment is started, the flat copper wire coil is installed on the wire coil power mechanism of the pre-feed section. The pre-feed section adopts a left-right double-sided layout, with the left side being line A and the right side being line B, realizing redundant wire supply with one in use and one in reserve. When the copper wire of line A is exhausted, the control system automatically sends a switching signal, and line B seamlessly takes over to continue supplying wire, while issuing a material change alarm. After the copper wire is straightened by the straightening mechanism, it enters the paint removal section, where four circumferentially distributed laser heads scan and erode the paint layer on the surface of the copper wire. Subsequently, the linear motor of the cutting section drives the left and right grippers to alternately move, accurately feeding the copper wire to the preset length and cutting it by the cutter. The cut copper wire segment is picked up by the transfer mechanism of the bending and forming section and sent into the one-to-two channel for diversion, and then undergoes U-shaped pre-bending in the plane.

[0057] The pre-bent copper wire is placed into the loading station fixture of the 3D forming section. The fixture moves along the circular guide rail with the magnetic levitation mover. The left magnetic levitation loop runs counterclockwise, and the right magnetic levitation loop runs clockwise. The two are mirror symmetrical. The copper wire passes through the height adjustment station to press the end down to the target layer height. It is then bent into an end insulation shape through the roof bottle cap forming station. The staggered bending forming station forms a staggered avoidance structure for adjacent copper wires in the same slot. The splitting forming arc forming station bends the cross-slot arc. Finally, the electrical performance is tested at the post-forming withstand voltage testing station. The qualified copper wire is removed by the dual robots of the automatic braiding winding section and inserted into the spool according to the preset insertion sequence to complete the final braiding of the stator winding.

[0058] Example 2

[0059] Please see Figure 1-7 Based on Embodiment 1, this invention provides an improved buffering and straightening mechanism for the pre-feed line section, the details of which are as follows:

[0060] The pre-feed section includes a wire reel power mechanism, a buffer mechanism one, a wire feeding drive mechanism, a buffer mechanism two, and a straightening mechanism. The wire reel power mechanism is an active wire feeding frame driven by a servo motor. It performs PID speed regulation based on the position feedback of the floating swing arm in buffer mechanism one to achieve active wire feeding. Buffer mechanism one is a set of floating guide wheels with tension provided by cylinders or gravity, which can absorb sudden tension changes when the wire reel reverses direction or starts and stops.

[0061] The wire feeding drive mechanism uses a pair of rubber pressure rollers driven by servo motors, which are the main driving force source. They pull the copper wire out of the buffer mechanism one and feed it into the buffer mechanism two. The structure of the buffer mechanism two is the same as that of the buffer mechanism one. It is set between the wire feeding drive mechanism and the straightening mechanism to isolate the influence of the previous wire feeding fluctuation on the straightening and subsequent high-speed cutting.

[0062] The straightening mechanism consists of multiple sets of straightening rollers arranged alternately in the horizontal and vertical directions. The copper wire passes between the straightening rollers. By adjusting the pressing amount of the rollers, the copper wire is made to undergo reverse plastic bending, thereby eliminating the curling stress of the raw material itself. After straightening, the straightness error of the copper wire is no more than 0.1 mm / m, which meets the feeding requirements for subsequent precision forming.

[0063] Traditional wire feeding methods in the industry mostly use passive wire feeding frames, which pull the copper wire from the wire coil by the pulling force of the subsequent wire feeding mechanism. This method has a fatal flaw: when the wire coil is heavy (usually 100-200kg), the moment of inertia of the wire coil is very large. The start and stop of the wire feeding mechanism will generate violent tension fluctuations. The measured peak tension can reach 3-5 times the steady state value. This tension impact can cause tensile scratches on the surface of the copper wire, or even cause irreversible bending deformation of the copper wire before it enters the subsequent mold. In addition, the traditional straightening method uses a fixed roller group. For copper wires of different diameters (such as 2mm and 4mm), the roller spacing needs to be adjusted manually. The changeover time is usually 30-60 minutes, and it depends on the experience of the workers, making it difficult to guarantee the consistency of straightening.

[0064] This invention employs a servo-driven active wire feeding mechanism combined with a two-stage floating buffer mechanism, fundamentally solving the aforementioned problems. Actual test data shows that under the PID control of active wire feeding, the copper wire tension fluctuation can be controlled within ±5%, far superior to the ±50% fluctuation range of passive wire feeding. The first buffer mechanism is equivalent to a mechanical low-pass filter, capable of filtering out high-frequency tension components above 10Hz. The second buffer mechanism isolates the impact caused by the high-speed start-stop (acceleration up to 5g) of the cutting section, ensuring that the copper wire tension entering the straightening mechanism remains constant. The straightness of the copper wire after straightening by this invention can reach below 0.08mm / m, far superior to the 0.2-0.5mm / m of the traditional method. In addition, the straightening rollers of this invention use a servo motor to drive the lead screw to automatically adjust the pressing amount. When changing types, simply select the corresponding copper wire specification in the control system, and the roller spacing will automatically adjust to the correct position. The changeover time is no more than 2 minutes, greatly improving the flexibility of the equipment.

[0065] Example 3

[0066] Please see Figure 1-7 Based on the above embodiments, the present invention provides an improved laser circumferential scanning and dust removal mechanism for the paint removal section, the details of which are as follows:

[0067] The paint removal section includes a support mechanism, a paint removal transverse movement mechanism, a paint removal laser head, a laser head focal length adjustment mechanism, and a dust collection chamber mechanism. The support mechanism consists of a pair of V-shaped support blocks and a pair of pneumatic clamping blocks. The copper wire passes through the center of the support block, and the clamping blocks press the copper wire into the V-shaped groove to prevent bending and deformation due to thermal stress during laser ablation.

[0068] Four laser heads for removing varnish are evenly distributed at 90-degree intervals around the central axis of the copper wire. Each laser head is independently mounted on a miniature linear module (i.e., the varnish removal transverse movement mechanism), which is arranged along the axial direction of the copper wire. During varnish removal, the four laser heads move synchronously along the axial direction of the copper wire and emit laser pulses at the same time, forming a continuous scanning band around the circumference of the copper wire, completely ablating and vaporizing the insulating varnish within a specified length (e.g., 25 mm).

[0069] The laser head focal length adjustment mechanism is a servo-driven lead screw and nut assembly connected to the laser head. It automatically adjusts the distance between the laser head and the surface of the copper wire according to the diameter of the copper wire, ensuring that the focal point falls precisely on the surface of the enamel layer, improving the enamel removal efficiency and avoiding damage to the copper wire substrate.

[0070] The dust collection chamber is located below the copper wire, with its suction port facing the laser scanning area. Connected to an industrial-grade high-flow-rate negative pressure dust collector, the chamber continuously draws in dust during the laser paint removal process, quickly removing vaporized dust and peeled residue to ensure a clean laser path and a clean workshop environment.

[0071] Currently, there are two main methods for removing varnish from flat wire motors. The first is mechanical scraping, which uses rotating blades or scrapers to physically peel off the varnish layer from the surface of the copper wire. Although this method has low equipment costs, it has significant problems: the blades are consumable parts and need to be replaced every 1,000-2,000 copper wires processed. Moreover, the scraping depth is difficult to control precisely, often resulting in damage to the copper wire substrate (leading to a reduction in cross-sectional area and an increase in resistance) or incomplete scraping (residual varnish layer affects subsequent soldering). The defect rate is usually 3-5%. The second method is chemical immersion, which involves immersing the copper wire in a strong acid or strong alkali solution to dissolve the varnish layer. This method is inefficient (each immersion takes 10-30 minutes) and generates a large amount of toxic waste liquid, resulting in extremely high environmental treatment costs and failing to comply with increasingly stringent environmental regulations.

[0072] This invention utilizes laser coating removal, offering significant advantages. Laser processing is non-contact, eliminating tool wear issues and theoretically allowing for continuous operation for tens of thousands of hours without consumable replacement. For example, actual test data shows that for polyimide insulating coatings approximately 0.05-0.08mm thick, using a 100W pulsed laser at a scanning speed of 200mm / s, the coating removal time for a single copper wire is only 0.3-0.5 seconds. This is 4-6 times more efficient than mechanical scraping (approximately 2-3 seconds per wire) and tens of times more efficient than chemical immersion methods. More importantly, by precisely controlling the laser pulse energy and focal length, the paint removal depth can be precisely controlled within the paint layer thickness range, resulting in almost zero damage to the copper wire substrate. After paint removal, the surface roughness of the copper wire Ra is ≤1.6μm, which is better than the Ra≥3.2μm of mechanical paint scraping. According to statistics, the defect rate of laser paint removal of this invention can be controlled below 0.2%, which is an order of magnitude lower than the traditional method. In addition, with the negative pressure suction of the dust collection chamber mechanism, the trace dust generated during paint removal is completely collected and filtered, with no waste gas or waste liquid discharged, meeting the requirements of clean production.

[0073] Example 4

[0074] Please see Figure 1-7 Based on the above embodiments, the present invention describes the alternating relay wire feeding mechanism of the cutting section:

[0075] The cutting section includes a right wire feeding motor, a right gripper, a left wire feeding motor, and a left gripper. The right and left grippers are driven by independent cylinders to clamp and release. Both the right and left wire feeding motors are linear motors, which drive the right and left grippers to reciprocate along the copper wire feeding direction.

[0076] The specific work cycle is:

[0077] The first step is to clamp the copper wire with the right jaw and release the left jaw. At this time, the right wire feeding motor moves forward (in the wire feeding direction) to drive the copper wire forward. At the same time, the left wire feeding motor moves backward to make room for the left jaw to clamp again.

[0078] The second step is that when the right wire feeding motor moves to the front limit position, the left gripper closes and clamps the copper wire, and the right gripper immediately releases.

[0079] The third step is to move the left wire feeding motor forward to continue pushing the copper wire forward, while the right wire feeding motor moves backward to the initial position.

[0080] Fourth step: the right gripper closes and clamps, the left gripper opens, and the right wire feeding motor moves forward again, and so on in a cycle.

[0081] The alternating wire feeding method ensures that the copper wire is fed continuously without interruption, avoiding the time wasted due to the return stroke required by the traditional screw wire feeding method. This significantly improves the wire feeding speed, which can reach more than 2m / s. When the cumulative length of the wire fed reaches the preset copper wire segment length, the punching mechanism located at the end of the wire feeding channel is activated to cut the copper wire.

[0082] In traditional flat wire forming equipment, copper wire feeding is mostly done by servo motor-driven roller pressing or screw and nut pushing. Although the roller pressing method is faster, it has the problem of slippage, especially when there is residual lubricating oil on the surface of the flat wire. The wire feeding length error can reach more than ±0.5mm, which obviously cannot meet the requirements of subsequent forming accuracy (±0.1mm). The screw and nut pushing method has higher accuracy, but it is limited by the stroke and return time of the screw, and its wire feeding speed is usually only 0.3-0.5m / s. Moreover, the screw must retract after each wire feeding before the next feeding can be carried out, which has a significant waiting time and greatly restricts the production cycle of the entire line.

[0083] This invention employs a linear motor-driven, dual-gripper alternating-feeding scheme, combining the advantages of high speed and high precision. The linear motor has no mechanical contact transmission components, directly generating linear thrust with extremely fast acceleration and deceleration response (up to 10g or more). Combined with a high-resolution grating ruler (0.001mm resolution), it forms a fully closed-loop position control, achieving a wire feeding length accuracy of ±0.03mm, far exceeding roller-based feeding methods. In terms of speed, due to the alternating force of the left and right grippers, the wire feeding process is completely continuous with no return travel time. The average wire feeding speed, as measured, reaches 2.5m / s, which is 5-8 times faster than the lead screw feeding method. Taking a typical 800mm copper wire segment as an example, traditional lead screw feeding (including return travel) takes approximately 3-4 seconds, while this invention only takes 0.3-0.4 seconds. In the overall production line cycle time calculation, this single-process efficiency improvement contributes approximately 40% to the overall production capacity, making it a key technological guarantee for achieving high output (designed capacity ≥30 pieces / hour).

[0084] Example 5

[0085] Please see Figure 1-7 Based on the above embodiments, the present invention describes the one-to-two splitting and rotary bending mechanism of the bending forming part:

[0086] The bending and forming part includes a material picking and punching mechanism, a transfer mechanism, a wire pushing mechanism, a wire feeding mechanism, a bending and forming mechanism, and a material unloading mechanism. The material picking and punching mechanism is the aforementioned punching mechanism, which, while cutting the copper wire, uses the inertia after punching or an air blowing device to send the end of the copper wire into the jaws of the transfer mechanism.

[0087] The transfer mechanism is a dual-channel linear motor module with two independently movable picking jaws. When a cut copper wire is received, the two jaws hold the two ends of the copper wire respectively and transfer it laterally from the cutting station to the splitting track. The splitting track is Y-shaped and distributes the single copper wire to the left or right channel in sequence.

[0088] After the copper wire enters the pushing mechanism, it is pushed along the guide groove into the feeding mechanism by the pushing cylinder. The feeding mechanism includes a movable chuck, which clamps one end of the copper wire and pushes it forward a preset distance. The bending and forming mechanism is a rotary bending head with a cavity adapted to the cross-section of the copper wire. When the feeding mechanism feeds the copper wire into the cavity, the rotary bending head rotates around its central axis at a certain angle (precisely controlled by a servo motor), and the copper wire undergoes plastic bending under the constraint of the cavity.

[0089] After bending, the unloading mechanism (a pneumatic gripper) holds the middle of the formed copper wire, removes it from the bending station, and places it on the receiving tray of the 3D forming part or directly into the fixture of the loading station. Since the wire pushing mechanism, wire feeding mechanism, bending forming mechanism and unloading mechanism are all arranged on both the left and right sides, the bending forming part can process copper wires from two channels at the same time, and the bending cycle time is no more than 1.2 seconds / piece.

[0090] Traditional flat wire bending often employs a one-time forming method using stamping dies. This involves using a complex multi-station progressive die to simultaneously complete the punching and bending actions at multiple angles within a single stamping stroke. While this method offers a fast cycle time, it suffers from two significant drawbacks: First, the die manufacturing cycle is long and costly, and once the design is finalized, its adaptability to different product specifications is extremely poor, often requiring the replacement of the entire die set when changing designs. Second, during the stamping process, the tensile and compressive stresses of the copper wire are concentrated, easily leading to cracks or wrinkles at the four corners of the rectangular cross-section. This is especially true for flat wires with a large width-to-thickness ratio (e.g., 4mm wide and 2mm thick), where the tensile stress on the outer side of the bend can easily cause micro-cracks in the copper wire matrix, affecting the long-term reliability of the motor.

[0091] This invention uses a rotary bending method to replace traditional stamping. During the rotary bending process, the copper wire gradually bends under the guidance of the cavity, resulting in a more uniform stress distribution within the deformation zone and avoiding stress concentration. Actual measurement data shows that the thinning rate of the copper wire on the outer side after bending is controlled within 8%, far superior to the 15-20% of the stamping method, and the surface is free of any cracks or wrinkles, significantly improving the service life of the winding. Regarding flexibility, the rotation angle of the bending forming mechanism is directly controlled by a servo motor. For different bending angle requirements, only the angle parameters in the control program need to be modified, without changing any molds. The changeover is completed within seconds. Furthermore, the split-design of the transfer mechanism allows the workload that originally required two machines to be completed in one machine through a dual-channel parallel process. This not only saves on equipment purchase costs but also eliminates the intermediate transfer link between the two machines, further improving the continuity and reliability of the entire production line.

[0092] Example 6

[0093] Please see Figure 1-7 Based on the above embodiments, this invention describes the multi-station staggered bending and splitting arc forming mechanism of the 3D forming part:

[0094] The 3D molding section is a dual-channel system, consisting of a left magnetic levitation loop and a right magnetic levitation loop. Each loop is a closed track composed of straight and curved segments. Multiple movers driven by linear motors run on the track, and each mover is fixed with a fixture. The fixture has an openable clamping mechanism for holding copper wires.

[0095] The height adjustment station is equipped with a Z-axis servo pressure bar. The end of the pressure bar has a pressure head that matches the cross-section of the copper wire. When the fixture carrying the copper wire arrives at the station, the pressure bar moves downward or upward to bend the end of the copper wire to a preset height layer to accommodate the wiring requirements of different layers of the stator winding.

[0096] The roof bottle cap forming station is equipped with a lateral extrusion mold. This mold applies pressure from the side and top of the copper wire simultaneously, bending the end of the copper wire into a pointed shape similar to a "roof" or an arc shape similar to a "bottle cap". This shape helps to increase the creepage distance between adjacent windings at the motor end and improve insulation safety.

[0097] The staggered bending forming station is equipped with multiple sets of independently operable sliding wedges. Each set of wedges applies lateral extrusion force to the copper wire from different directions. Since adjacent pins of the copper wire in the same layer need to be inserted into different slots of the iron core, their ends must form staggered S-shaped or Z-shaped bends. This station forms a precise spatial staggered structure on the copper wire through step-by-step and zoned extrusion actions.

[0098] The splitting and forming arc station is equipped with a splitting knife and an arc forming die. The splitting knife is inserted along the tangential direction of the copper wire. By using the combined action of stretching and bending, the copper wire is formed into a smooth arc segment with a specific radius (such as R50-R200mm). This arc segment spans multiple slots of the stator core and is a key characteristic shape of the flat wire motor winding.

[0099] The withstand voltage testing station after molding is equipped with two sets of high-voltage probes. One set of probes is connected to a high-voltage generator, and the other set of probes is connected to a current detection circuit. The probes are driven by a cylinder to pierce or contact the de-varnished areas at both ends of the copper wire, apply the set high voltage, and detect whether the leakage current exceeds the standard. This determines whether the insulating varnish layer of the copper wire is intact after multiple bends.

[0100] For the three-dimensional forming of flat wire, there are two traditional approaches. One is to use multiple CNC bending machines connected in series, with each machine completing the bending in one direction. The copper wire is clamped and transferred multiple times between the machines. Since there is a positioning reference error in each clamping (the cumulative error can reach more than ±0.3mm), and the flat wire has a complex spatial shape after multiple bends, subsequent clamping is extremely difficult, often resulting in clamping deformation or inaccurate positioning, making it difficult to guarantee the accuracy of the final product. The second approach is to use a dedicated six-axis or seven-axis tube bending center. This equipment can complete bending in multiple directions within a single clamping station. However, such equipment is extremely expensive, and its processing capacity and efficiency are not ideal for the complex forming of flat wire motors, which require dense, small-pitch, and multi-angle bending.

[0101] This invention decomposes 3D molding into multiple independent, unidirectional or bidirectional simple molding actions, and arranges them into multiple dedicated workstations along a magnetic levitation ring line. Each workstation performs only a simple molding task (such as only performing Z-axis height adjustment, or only performing lateral staggered extrusion). The mold structure is simple, rigid, and reliable.

[0102] More importantly, the introduction of the magnetic levitation conveyor system reduces the cycle time of traditional stepper conveyors to a speed limited by the start and stop speed of the mechanical structure, with acceleration typically not exceeding 1g. In contrast, the acceleration of the magnetic levitation actuator can reach over 5g, reducing the transmission time between workstations from the traditional 1-2 seconds to less than 0.3 seconds. Taking the magnetic levitation loop on the left as an example, its counterclockwise continuous rotation allows the fixture to continuously circulate through each workstation without waiting for the workstation to reset, achieving true assembly line-style continuous production, which is unmatched by traditional intermittent conveyor lines.

[0103] Example 7

[0104] Please see Figure 1-7 Based on the above embodiments, the present invention describes a dual-robot cooperative wiring mechanism for automatically braided windings:

[0105] The automatic braided winding section is configured with two channels, consisting of a left winding section and a right winding section, corresponding to the unloading stations of the left and right magnetic levitation loops, respectively.

[0106] The left winding section includes a six-axis industrial robot, a material handling fixture, a guide plate intervention mechanism, an internal support spool mechanism, and a pressing mechanism. The robot takes out the formed three-dimensional copper wire from the fixture at the unloading station. The material handling fixture is a specially designed contour-following pneumatic gripper, whose gripping point coincides with the center of gravity of the copper wire to prevent the copper wire from deforming during the transfer process.

[0107] The robot moves the copper wire above the inner support spool mechanism. The inner support spool mechanism is a cylindrical structure with the same shape as the inside of the stator core. Slots corresponding to the stator slots are opened on its circumference. The guide plate intervention mechanism is a set of arc-shaped guide plates distributed along the circumference. It is driven by a cylinder to insert into the slot entrance of the spool, forming a trumpet-shaped guide opening.

[0108] The robot aligns the two pins of the copper wire with the guide openings of the corresponding slots on the spool. Then, the pressing mechanism applies downward pressure from above, pressing the copper wire into the slot of the spool along the guide opening. Each time a copper wire is inserted, the inner support spool mechanism rotates one slot pitch to prepare to receive the next copper wire. According to the preset winding wiring sequence (such as double-layer winding, concentric winding, etc.), the guide plate intervention mechanism, the inner support spool mechanism, and the pressing mechanism work in a coordinated manner until all the copper wires of a stator winding are inserted into the spool, completing the automatic weaving.

[0109] Winding braiding has long been the least automated and most labor-intensive process in the production of flat wire motors. Currently, most companies use manual wire insertion: the operator holds the shaped copper wire, aligns its two leads with the corresponding slots in the stator core, and uses a rubber hammer or special pressure rod to tap the copper wire into the slot. A typical 48-slot stator requires the insertion of 96 copper wires (double-layer winding). It takes a skilled worker about 40-60 minutes to complete all the insertions. Moreover, the long-term repetitive work easily leads to hand fatigue, and it is difficult to maintain consistent insertion force and angle. Problems such as incomplete insertion of copper wires and scratches on the insulation layer by the slot opening often occur.

[0110] This invention utilizes a six-axis industrial robot with specialized tooling to achieve complete automation of the wire insertion process. The robot's positioning accuracy can reach ±0.05mm, far exceeding the accuracy of human operation. Furthermore, the force, angle, and speed of each wire insertion can be precisely set and perfectly reproduced by the program, fundamentally ensuring the consistency of product quality. The trumpet-shaped guide port design of the guide plate intervention mechanism expands the inlet width of the slot from approximately 2mm (actual slot width) to approximately 10mm, greatly reducing the difficulty of robot alignment. At the same time, it effectively prevents the copper wire from being scratched by the slot edge at the inlet. This is a key design detail that ensures a high yield rate.

[0111] In addition, the dual-robot collaborative operation (the left and right winding sections correspond to the two magnetic levitation loops of the 3D forming section respectively) allows the equipment to perform material picking and positioning actions simultaneously while inserting one stator, achieving seamless connection of the wire insertion process and further maximizing the overall production capacity of the line.

[0112] Example 8

[0113] Please see Figure 1-7 Based on the above embodiments, the present invention provides an operation method compatible with the implementation device, specifically:

[0114] A method for forming stator windings for flat wire motor production includes the following steps:

[0115] Step 1, the pre-feeding step, uses one of at least two switchable pre-feeding mechanisms to supply copper wire to the equipment, so that the copper wire passes through the unwinding of the wire winding power mechanism, the tension buffering of the buffer mechanism one, the active wire feeding of the wire feeding drive mechanism, the tension buffering of the buffer mechanism two again, and the multi-stage straightening process of the straightening mechanism to obtain flat copper wire that meets the straightness requirements.

[0116] Step 2, laser paint removal step: The copper wire is supported and positioned by the support mechanism. The paint removal transverse movement mechanism moves multiple circumferentially distributed paint removal laser heads to the position of the copper wire where paint needs to be removed. After the laser head focal length adjustment mechanism adjusts the focal position, the laser ablation is started to remove the insulating varnish layer. At the same time, the dust collection chamber mechanism collects dust from the paint removal area.

[0117] Step 3, continuous wire feeding and cutting step: the copper wire is clamped alternately by the right and left jaws, and the copper wire is continuously fed in a relay manner by the right and left wire feeding motors. After being fed to the preset length, the copper wire is cut by the material picking and punching mechanism.

[0118] Step four, planar bending and forming step: the cut copper wire is diverted to any one of at least two processing channels by the transfer mechanism, the copper wire is pushed into the wire feeding mechanism by the wire pushing mechanism, the wire feeding mechanism and the bending and forming mechanism cooperate to bend the copper wire into a preset two-dimensional shape in the plane, and the formed wire is output by the unloading mechanism.

[0119] Step 5, the three-dimensional forming step, places the copper wire after planar bending on the loading station of any one of at least two independently operating circular magnetic levitation conveyor lines, so that the copper wire passes through the height adjustment station, the roof bottle cap forming station, the staggered bending forming station, and the splitting forming arc station in sequence to be bent and formed in three-dimensional space. After being tested for pressure resistance at the forming pressure resistance testing station, it is output from the unloading station.

[0120] Step six, automatic weaving step: The robot, in conjunction with the material handling fixture, takes the three-dimensional shaped copper wire that has passed the pressure resistance test from the unloading station. After being guided by the guide plate intervention mechanism, it is inserted into the corresponding slots of the inner support spool mechanism in sequence. The pressing mechanism presses the copper wire into place, completing the automatic weaving of the winding.

[0121] In step one above, there are two sets of pre-feeding mechanisms arranged on both the left and right sides. When the copper wire of the working pre-feeding mechanism runs out, the control system automatically switches to another pre-feeding mechanism to continue feeding wire, realizing material change without stopping the machine. The straightening mechanism includes multiple sets of straightening rollers arranged in an alternating pattern. The pressing amount of the straightening rollers is automatically adjusted according to the diameter specification of the current copper wire.

[0122] In step two above, four paint-removing laser heads are distributed circumferentially around the copper wire at 90-degree intervals. During paint removal, the four laser heads move synchronously along the copper wire axis under the drive of the paint removal transverse movement mechanism, forming a continuous scanning band around the copper wire to complete the paint layer ablation. The dust suction chamber mechanism is set on one side of the copper wire with the dust suction port facing the scanning area of ​​the paint-removing laser head, and continuous suction is performed during the paint removal process. After the paint removal is completed, the quality of the copper wire surface in the paint removal area is judged by visual inspection.

[0123] In summary, the specific implementation of this invention in the stator winding of flat wire motors achieves full-process automation. From raw copper wire to the finished winding, all processes are automatically completed by the equipment without manual intervention, greatly improving production efficiency and reducing labor costs. Furthermore, the magnetic levitation ring conveyor line enables precise positioning and high-speed transmission during the 3D forming process. Combined with a multi-station step-by-step forming strategy, it effectively controls the springback and distortion of the flat wire when bending in three-dimensional space, significantly improving the dimensional accuracy and consistency of the winding. In addition, it has extremely high system flexibility. The one-use-one-standby design of the pre-feeding section allows for material change without stopping the machine. The alternating clamping and feeding of the cutting section can adapt to copper wire segments of different lengths. Each forming station in the 3D forming section is servo-driven, and the stamping stroke and angle can be adjusted by the program to achieve rapid shape change and meet the production needs of flat wire motors of various specifications.

[0124] The embodiments of the present invention have been described above, but the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the present invention, all of which are within the protection scope of the present invention.

Claims

1. A stator winding forming equipment for producing flat wire motors for new energy vehicles, characterized in that, It includes a pre-feeding line section, a paint removal section, a cutting section, a bending and forming section, a 3D forming section, and an automatic braiding winding section arranged sequentially along the material flow direction; The pre-feeding section is equipped with at least two sets of switchable pre-feeding mechanisms. Each pre-feeding mechanism is provided with a wire winding power mechanism, a buffer mechanism one, a wire feeding drive mechanism, a buffer mechanism two, and a straightening mechanism in sequence along the copper wire conveying direction. These mechanisms are used to straighten the copper wire until it meets the straightness requirements of the process before outputting it. The paint removal section is equipped with a laser paint removal module, which includes a support mechanism, a paint removal transverse movement mechanism, multiple circumferentially distributed paint removal laser heads, a laser head focal length adjustment mechanism, and a dust suction cavity mechanism corresponding to the paint removal laser heads, for laser ablation and removal of the insulating varnish layer at a specified location on the copper wire. The cutting section is equipped with a linear motor driven wire feeding module and an alternating clamping module. The linear motor driven wire feeding module includes a right wire feeding motor and a left wire feeding motor. The alternating clamping module includes a right jaw and a left jaw, which are used to realize the continuous feeding of copper wire and cutting at a preset length. The bending and forming section is equipped with a material picking and punching mechanism, a transfer mechanism, a wire pushing mechanism, a wire feeding mechanism, a bending and forming mechanism, and a material unloading mechanism. The transfer mechanism is used to divert the cut copper wire to at least two processing channels. The wire feeding mechanism cooperates with the bending and forming mechanism to complete the planar bending and forming of the copper wire. The 3D forming section is equipped with at least two independently operating annular magnetic levitation conveyor lines. Each annular magnetic levitation conveyor line is sequentially equipped with a feeding station, a height adjustment station, a roof bottle cap forming station, a staggered bending forming station, a splitting forming arc station, a forming pressure resistance testing station, and a unloading station, which are used to perform three-dimensional spatial forming of copper wire after planar bending. The automatic braiding winding section is equipped with robot insertion and picking modules that match the number of the annular magnetic levitation conveyor lines. Each robot insertion and picking module includes a robot, a material picking fixture, a guide plate intervention mechanism, an inner support spool mechanism, and a pressing mechanism, which are used to insert the three-dimensionally formed copper wires into the spools in sequence to complete the winding braiding.

2. The stator winding forming equipment for producing flat wire motors for new energy vehicles according to claim 1, characterized in that, The pre-feeding line section has two sets of pre-feeding mechanisms, arranged on both sides with one in use and one as a backup; the buffer mechanism one and buffer mechanism two are floating guide wheel group structures, and the straightening mechanism includes multiple sets of straightening rollers arranged in an alternating manner.

3. The stator winding forming equipment for producing flat wire motors for new energy vehicles according to claim 1, characterized in that, The plurality of paint removal laser heads are four in number, circumferentially distributed around the copper wire at 90-degree intervals; the paint removal transverse movement mechanism is used to drive the paint removal laser head to move along the copper wire axis to the position where paint needs to be removed; the laser head focal length adjustment mechanism is used to adjust the focal point of the paint removal laser head to the paint layer surface; the dust suction chamber mechanism is located on one side of the copper wire and the dust suction port is directly opposite the scanning area of ​​the paint removal laser head.

4. The stator winding forming equipment for producing flat wire motors for new energy vehicles according to claim 1, characterized in that, The right and left grippers alternately clamp and release under the coordination of the control system. The right wire feeding motor drives the right gripper to reciprocate, and the left wire feeding motor drives the left gripper to reciprocate. The right and left wire feeding motors drive each other alternately to achieve continuous relay feeding of copper wire.

5. The stator winding forming equipment for producing flat wire motors for new energy vehicles according to claim 1, characterized in that, The transfer mechanism is a linear motor module with dual channels, used to laterally transfer the cut copper wire from the cutting station and alternately distribute it to the two processing channels. The wire pushing mechanism is used to push the copper wire into the wire feeding mechanism. The wire feeding mechanism and the bending and forming mechanism work together synchronously to complete the bending and forming of the copper wire. The bending and forming mechanism bends the copper wire into a preset two-dimensional shape by rotational bending. The wire pushing mechanism, wire feeding mechanism, bending and forming mechanism and unloading mechanism are arranged on both the left and right sides in the bending and forming part.

6. The stator winding forming equipment for producing flat wire motors for new energy vehicles according to claim 1, characterized in that, There are two circular magnetic levitation conveyor lines, namely a left magnetic levitation and a right magnetic levitation, arranged in a mirror image layout. The loading station, height adjustment station, roof bottle cap forming station, staggered bending forming station, split forming arc station, post-forming pressure resistance testing station, and unloading station are arranged in a mirror image layout on the left and right magnetic levitations. The running direction of the left magnetic levitation is opposite to that of the right magnetic levitation.

7. The stator winding forming equipment for producing flat wire motors for new energy vehicles according to claim 1, characterized in that, The robot has two insertion / removal modules, namely the left winding section and the right winding section, which are respectively set up at the unloading stations of the left and right magnetic levitation. The guide plate intervention mechanism is a retractable guide plate structure, which is used to expand the guide width of the spool slot entrance when the copper wire is inserted into the spool. The inner support spool mechanism is a cylindrical structure adapted to the internal shape of the stator core, and its circumferential surface is provided with slots corresponding to the stator slots. The pressing mechanism is used to apply an insertion force in a set direction to the copper wire, pressing the copper wire into the corresponding slot of the inner support spool mechanism.

8. A method for forming stator windings for producing flat wire motors, employing a stator winding forming device for producing flat wire motors for new energy vehicles as described in any one of claims 1-7, characterized in that, Includes the following steps: Step 1, the pre-feeding step, uses one of at least two switchable pre-feeding mechanisms to supply copper wire to the equipment, so that the copper wire passes through the unwinding of the wire winding power mechanism, the tension buffering of the buffer mechanism one, the active wire feeding of the wire feeding drive mechanism, the tension buffering of the buffer mechanism two again, and the multi-stage straightening process of the straightening mechanism to obtain flat copper wire that meets the straightness requirements. Step 2, laser paint removal step: The copper wire is supported and positioned by the support mechanism. The paint removal transverse movement mechanism moves multiple circumferentially distributed paint removal laser heads to the position of the copper wire where paint needs to be removed. After the laser head focal length adjustment mechanism adjusts the focal position, the laser ablation is started to remove the insulating varnish layer. At the same time, the dust collection chamber mechanism collects dust from the paint removal area. Step 3, continuous wire feeding and cutting step: the copper wire is clamped alternately by the right and left jaws, and the copper wire is continuously fed in a relay manner by the right and left wire feeding motors. After being fed to the preset length, the copper wire is cut by the material picking and punching mechanism. Step four, planar bending and forming step: the cut copper wire is diverted to any one of at least two processing channels by the transfer mechanism, the copper wire is pushed into the wire feeding mechanism by the wire pushing mechanism, the wire feeding mechanism and the bending and forming mechanism cooperate to bend the copper wire into a preset two-dimensional shape in the plane, and the formed wire is output by the unloading mechanism. Step 5, the three-dimensional forming step, places the copper wire after planar bending on the loading station of any one of at least two independently operating circular magnetic levitation conveyor lines, so that the copper wire passes through the height adjustment station, the roof bottle cap forming station, the staggered bending forming station, and the splitting forming arc station in sequence to be bent and formed in three-dimensional space. After being tested for pressure resistance at the forming pressure resistance testing station, it is output from the unloading station. Step six, automatic weaving step: The robot, in conjunction with the material handling fixture, takes the three-dimensional shaped copper wire that has passed the pressure resistance test from the unloading station. After being guided by the guide plate intervention mechanism, it is inserted into the corresponding slots of the inner support spool mechanism in sequence. The pressing mechanism presses the copper wire into place, completing the automatic weaving of the winding.

9. A method for forming a stator winding for producing a flat wire motor according to claim 8, characterized in that, In step one, there are two sets of pre-feeding mechanisms arranged on both the left and right sides. When the copper wire of the working pre-feeding mechanism runs out, the control system automatically switches to another pre-feeding mechanism to continue feeding wire, realizing material change without stopping the machine. The straightening mechanism includes multiple sets of straightening rollers arranged in an alternating pattern. The pressing amount of the straightening rollers is automatically adjusted according to the diameter specification of the current copper wire.

10. A method for forming a stator winding for producing a flat wire motor according to claim 8, characterized in that, In step two, four paint-removing laser heads are distributed circumferentially around the copper wire at 90-degree intervals. During paint removal, the four laser heads move synchronously along the copper wire axis under the drive of the paint removal transverse movement mechanism, forming a continuous scanning band around the copper wire to complete the paint layer ablation. The dust suction chamber mechanism is set on one side of the copper wire with the dust suction port facing the scanning area of ​​the paint-removing laser head, and continuous suction is performed during the paint removal process. After the paint removal is completed, the quality of the copper wire surface in the paint removal area is judged by visual inspection.

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