Stator assembly head twisting method for new energy vehicle with same layer wire head and different twist angles

Abstract

The application discloses a new energy vehicle stator assembly with different twist angles of the same layer wire head, and a twist head method thereof, which comprises the following steps: S1: aligning a twist head mold with the stator assembly, and rotating each layer of twist head wire disc in the twist head mold to align the lead-out wire slot in each layer of twist head wire disc with the corresponding lead-out wire head in the corresponding layer wire head of the stator assembly; S2: inserting the free end of the lead-out wire head into the corresponding lead-out wire slot in the corresponding twist head wire disc in the axial direction; S3: rotating each layer of twist head wire disc to align the welding wire slot in each layer of twist head wire disc with the corresponding welding wire head in the corresponding layer wire head; S4: inserting the free end of the welding wire head in the stator assembly into the corresponding welding wire slot in the corresponding twist head wire disc in the axial direction; and S5: rotating each layer of twist head wire disc to drive the lead-out wire head inserted into the lead-out wire slot and the welding wire head inserted into the welding wire slot to form the twist angle.

Description

Technical Field

[0001] This invention relates to a method for twisting the stator assembly of a new energy vehicle with different twist angles at the same layer of wire ends. Background Technology

[0002] Currently, in the manufacturing process of flat wire motor stator assemblies, after the hairpin wire is inserted into the slot and flared, the stator assembly needs to be twisted, that is, the wire ends at the end of the stator assembly are twisted and shaped according to the design angle. The multi-layer twisting device and twisting machine disclosed in patent CN114337134B and the motor stator flat copper wire twisting device disclosed in patent CN214755982U can both perform twisting processing on the stator assembly.

[0003] In stator assemblies, wire ends are typically distributed in several layers from the inside out, such as 4, 6, or 8 layers. Existing methods require that the twist angles of the wire ends within the same layer be identical during stator assembly twisting. However, in a new type of stator assembly, both welded wire ends and lead-out wire ends exist within the same layer. The twist angles required for the lead-out wire ends differ from those required for the welded wire ends. This results in inconsistent twist angles for the wire ends within the same layer of the stator assembly, and existing twisting methods cannot accommodate these different twist angles for the lead-out and welded wire ends located within the same layer of the stator assembly. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to overcome the defects of the prior art and provide a method for twisting the stator assembly of new energy vehicles with different twist angles of wire ends on the same layer. It can twist the lead wire ends and welding wire ends located on the same layer of the stator assembly at different angles.

[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is: a method for twisting stator assemblies for new energy vehicles with different torsion angles at the same layer of wire ends, the method being implemented based on a twisting mold and used to twist the stator assembly;

[0006] The stator assembly has N layers of wire ends arranged sequentially from the inside to the outside. Each layer of wire ends has a solder wire end and a lead wire end. The lead wire end is longer than the solder wire end, where N≥2.

[0007] The twisting head mold includes N layers of twisting head coils arranged sequentially from the inside to the outside. The N layers of twisting head coils correspond one-to-one with the N layers of wire ends in the stator assembly. Each twisting head coil has a lead wire groove corresponding to the lead wire end in the corresponding layer of wire ends. The twisting head coil also has a welding wire groove corresponding to the welding wire end in the corresponding layer of wire ends. When the lead wire groove in the twisting head coil is aligned with the corresponding lead wire end in the corresponding layer of wire ends in the stator assembly, the welding wire groove in the twisting head coil is misaligned with the corresponding welding wire end in the corresponding layer of wire ends.

[0008] The steps of the method include:

[0009] S1: Align the torsion head mold with the stator assembly, rotate each layer of torsion head coil in the torsion head mold so that the lead wire groove in each layer of torsion head coil is aligned with the corresponding lead wire in the corresponding layer of the stator assembly. At this time, the welding wire groove in each layer of torsion head coil is misaligned with the corresponding welding wire in the corresponding layer of the stator assembly.

[0010] S2: Insert the free end of the lead wire into the corresponding lead wire slot in the corresponding twist head coil along the axial direction, and keep the welding wire end out of the welding wire slot;

[0011] S3: Rotate each layer of twisting head coils to align the welding wire grooves in each layer of twisting head coils with the corresponding welding wire ends in the corresponding layer of wire ends. At this time, the lead wire ends inserted into the lead wire grooves are pre-twisted by the twisting head coils at a certain angle.

[0012] S4: Insert the free end of the welding wire in the stator assembly into the corresponding welding wire groove in the corresponding twist head coil along the axial direction. At this time, the lead wire will be further inserted into the corresponding lead wire groove.

[0013] S5: Make each layer of twisting head coil rotate in the direction that the corresponding layer of wire head needs to be twisted, thereby driving the lead wire head inserted into the lead wire slot and the welding wire head inserted into the welding wire slot to twist and form the angle.

[0014] Furthermore, the i-th layer of twisting coil in the twisting head mold corresponds to the i-th layer of wire head in the stator assembly; where the i-th layer of twisting coil and the i-th layer of wire head are both the i-th layer from the inside out, i is an integer, 1≤i≤N;

[0015] In step S3, when rotating each layer of twisting head reels to align the welding grooves in each layer of twisting head reels with the corresponding welding ends in the corresponding layer of wire ends, the rotation angle of the i-th layer of twisting head reels is |α|. i -β i |, if α i >β i Then the rotation direction of the i-th layer twisting coil is opposite to the direction that the i-th layer thread head needs to be twisted, if α i <β i Then the rotation direction of the i-th layer twisting head reel is the same as the direction in which the i-th layer thread head needs to be twisted;

[0016] Where, α i β is the angle at which the soldered wire end in the i-th layer needs to be twisted. i Let be the angle at which the lead wire in the i-th layer needs to be twisted. The lead wires and soldered wires in the same layer need to be twisted in the same direction.

[0017] Furthermore, in step S5, when each layer of twisting coils rotates along the direction that the corresponding layer's wire end needs to be twisted, thereby causing the lead wire end inserted into the lead wire slot and the welding wire end inserted into the welding wire slot to form the twist angle, the rotation angle of the i-th layer twisting coil is α. i The rotation direction of the i-th layer twisting head reel is the same as the direction in which the i-th layer thread head needs to be twisted.

[0018] Further, the specific operation of step S2 is as follows: move one of the torsion head mold and the stator assembly toward the other of the torsion head mold and the stator assembly, so that the free end of the lead wire on the stator assembly is inserted axially into the corresponding lead wire groove in the corresponding torsion head coil, and keep the welding wire end not inserted into the welding wire groove.

[0019] Furthermore, the specific operation of step S4 is as follows: one of the torsion head mold and the stator assembly moves toward the other of the torsion head mold and the stator assembly, thereby inserting the free end of the welding wire head in the stator assembly into the corresponding welding wire groove in the corresponding torsion head coil along the axial direction, while simultaneously inserting the lead wire head in the stator assembly further into the corresponding lead wire groove along the axial direction.

[0020] Furthermore, the method is implemented based on a head-turning machine, wherein the head-turning mold is installed in the head-turning machine, and the head-turning machine is used to grasp the stator assembly and drive the stator assembly to move.

[0021] By employing the above technical solution, step S1 aligns the lead-out slots in each layer of the twisting coil with the corresponding lead-out ends in the corresponding layer of the wire head. At this time, the welding slots in each layer of the twisting coil are misaligned with the corresponding welding ends in the corresponding layer of the wire head. Since the lead-out ends are longer than the welding ends, step S2 allows the free end of the lead-out end in the stator assembly to be inserted into the corresponding lead-out slot in the corresponding twisting coil, while the welding ends in the stator assembly are not inserted into the welding slots. After step S3, the lead wire inserted into the lead wire slot will be pre-twisted by the twisting head coil at a certain angle. However, the welding wire is not pre-twisted because it is not inserted into the welding wire slot. In step S3, the welding wire slots in each layer of twisting head coils are aligned with the corresponding welding wires in the corresponding layer of wires. Then, in step S4, the free end of the welding wire in the stator assembly can be inserted axially into the corresponding welding wire slot in the corresponding twisting head coil. During the process of the welding wire being inserted axially into the welding wire slot, the lead wire will be inserted deeper into the corresponding lead wire slot. Then, in step S5, by rotating each layer of twisting head coils, the lead wire inserted into the lead wire slot and the welding wire inserted into the welding wire slot can be twisted to form the desired angle. In step S3, the lead wire ends in the same layer are pre-twisted by a certain angle, while the welding wire ends are not pre-twisted. In step S5, the lead wire ends and welding wire ends in the same layer are both twisted by the same angle, thus achieving the purpose of twisting the lead wire ends and welding wire ends in the same layer of the stator assembly by different angles. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the structure of the torsion head mold of the present invention;

[0023] Figure 2 This is a perspective sectional view of the torsion head mold of the present invention;

[0024] Figure 3 This is a schematic diagram of the stator assembly of the present invention before the torsion head;

[0025] Figure 4 This is a schematic diagram of the structure in step S2 of the present invention, in which the lead wire end is inserted into the lead wire groove and the welding wire end is not inserted into the welding wire groove.

[0026] Figure 5 This is a schematic diagram of the structure in step S4 of the present invention, in which the welding wire end is inserted into the welding wire groove;

[0027] Figure 6 This is a schematic diagram of the stator assembly of the present invention after the head is turned;

[0028] Figure 7 This is a schematic diagram of the structure of the torsion mold and stator assembly of the present invention installed in the torsion machine;

[0029] In the diagram: 1. Twisting head mold; 2. Stator assembly; 3. Welding wire end; 4. Lead-out wire end; 5. Twisting head reel; 6. Lead-out wire groove; 7. Welding wire groove. Detailed Implementation

[0030] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0031] like Figures 1-6 As shown, a method for twisting a stator assembly for a new energy vehicle with different twist angles at the same layer of wire ends is described. The method is implemented based on a twisting mold 1 and used to twist the stator assembly 2.

[0032] The stator assembly 2 has N layers of wire ends arranged sequentially from the inside to the outside. Each layer of wire ends has a welding wire end 3 and a lead wire end 4. The lead wire end 4 is longer than the welding wire end 3. N ≥ 2. The angle that the lead wire end 4 needs to be twisted in the same layer of wire ends is different from the angle that the welding wire end 3 needs to be twisted.

[0033] The twisting head mold 1 includes N layers of twisting head coils 5 arranged sequentially from the inside to the outside. The N layers of twisting head coils 5 correspond one-to-one with the N layers of wire ends in the stator assembly 2. Each twisting head coil 5 is provided with a lead wire groove 6 corresponding to the lead wire end 4 in the corresponding layer of wire ends. The twisting head coil 5 is also provided with a welding wire groove 7 corresponding to the welding wire end 3 in the corresponding layer of wire ends. When the lead wire groove 6 in the twisting head coil 5 is aligned with the corresponding lead wire end 4 in the corresponding layer of wire ends in the stator assembly 2, the welding wire groove 7 in the twisting head coil 5 is misaligned with the corresponding welding wire end 3 in the corresponding layer of wire ends.

[0034] The steps of the method include:

[0035] S1: Align the torsion head mold 1 with the stator assembly 2, and rotate each layer of torsion head coil 5 in the torsion head mold 1 so that the lead wire groove 6 in each layer of torsion head coil 5 is aligned with the corresponding lead wire 4 in the corresponding layer of wire head in the stator assembly 2. At this time, the welding wire groove 7 in each layer of torsion head coil 5 is misaligned with the corresponding welding wire 3 in the corresponding layer of wire head in the stator assembly 2.

[0036] S2: Insert the free end of the lead wire 4 into the corresponding lead wire groove 6 in the corresponding twist head coil 5 along the axial direction, and keep the welding wire 3 out of the welding groove 7.

[0037] S3: Rotate each layer of twisting head coil 5 to align the welding wire groove 7 in each layer of twisting head coil 5 with the corresponding welding wire head 3 in the corresponding layer of wire head. At this time, the lead wire head 4 inserted in the lead wire groove 6 is pre-twisted by the twisting head coil 5 at a certain angle.

[0038] S4: Insert the free end of the welding wire head 3 in the stator assembly 2 into the corresponding welding wire groove 7 in the corresponding twist head wire spool 5 along the axial direction. At this time, the lead wire head 4 will be further inserted into the corresponding lead wire groove 6.

[0039] S5: Make each layer of twisting head coil 5 rotate in the direction that the corresponding layer of wire head needs to be twisted, thereby driving the lead wire head 4 inserted into the lead wire groove 6 and the welding wire head 3 inserted into the welding wire groove 7 to twist and shape the angle.

[0040] Specifically, step S1 aligns the lead-out slots 6 in each layer of the twisting coil 5 with the corresponding lead-out ends 4 in the corresponding layer of the wire head. At this time, the welding slots 7 in each layer of the twisting coil 5 are misaligned with the corresponding welding ends 3 in the corresponding layer of the wire head. Since the lead-out ends 4 are longer than the welding ends 3, step S2 allows the free end of the lead-out ends 4 in the stator assembly 2 to be inserted into the corresponding lead-out slots 6 in the corresponding twisting coil 5, while the welding ends 3 in the stator assembly 2 are not inserted into the welding slots 7. After step S3, the lead wire 4 inserted into the lead wire groove 6 will be pre-twisted by the twisting coil 5 at a certain angle. The welding wire 3, because it is not inserted into the welding wire groove 7, is not pre-twisted. In step S3, the welding wire groove 7 in each layer of twisting coil 5 is aligned with the corresponding welding wire 3 in the corresponding layer of wire. Then, in step S4, the free end of the welding wire 3 in the stator assembly 2 can be inserted axially into the corresponding welding wire groove 7 in the corresponding twisting coil 5. During the process of the welding wire 3 being inserted axially into the welding wire groove 7, the lead wire 4 will be inserted deeper into the corresponding lead wire groove 6. Then, in step S5, by rotating each layer of twisting coil 5, the lead wire 4 inserted into the lead wire groove 6 and the welding wire 3 inserted into the welding wire groove 7 can be twisted to form the desired angle. In step S3, the lead wire 4 in the same layer is pre-twisted by a certain angle while the welding wire 3 is not pre-twisted. In step S5, the lead wire 4 and the welding wire 3 in the same layer are both twisted by the same angle, thus achieving the purpose of twisting the lead wire 4 and the welding wire 3 in the same layer of the stator assembly 2 by different angles.

[0041] Specifically, the lead-out groove 6 in the twisting coil 5 corresponds one-to-one with the lead-out wire 4 in the corresponding layer of wire ends, and the welding groove 7 in the twisting coil 5 corresponds one-to-one with the welding wire end 3 in the corresponding layer of wire ends. The twisting angle of the wire end refers to the central angle, that is, the angle between the line connecting the position of the wire end before twisting to the center of the circle and the line connecting the position of the wire end after twisting to the center of the circle.

[0042] Specifically, the i-th layer of twisting coil 5 in the twisting head mold 1 corresponds to the i-th layer of wire head in the stator assembly 2; where the i-th layer of twisting coil 5 and the i-th layer of wire head are both the i-th layer from the inside out, i is an integer, 1≤i≤N;

[0043] In step S3, when rotating each layer of twisting coil 5 to align the welding groove 7 in each layer of twisting coil 5 with the corresponding welding head 3 in the corresponding layer of wire head, the rotation angle of the i-th layer twisting coil 5 is |α|. i -β i |, if α i >β i Then the rotation direction of the i-th layer twisting coil 5 is opposite to the direction that the i-th layer thread head needs to be twisted, if α i <β i Then the rotation direction of the i-th layer twisting head spool 5 is the same as the direction that the i-th layer thread head needs to be twisted.

[0044] Where, α i β is the angle at which the solder joint 3 in the i-th layer needs to be twisted. i Let be the angle that the lead wire 4 in the i-th layer of wire ends needs to be twisted. The lead wire 4 and the solder wire end 3 in the same layer of wire ends need to be twisted in the same direction. Specifically, the direction that the wire end needs to be twisted refers to the direction of twisting of the wire end from the final twisted position to the initial position, and the angle that the wire end needs to be twisted refers to the angle that the wire end needs to twist from the initial position to the final twisted position.

[0045] Specifically, in step S5, when each layer of twisting coil 5 rotates along the direction that the corresponding layer of wire ends needs to be twisted, thereby causing the lead wire end 4 inserted into the lead wire groove 6 and the welding wire end 3 inserted into the welding wire groove 7 to be twisted at the desired angle, the rotation angle of the i-th layer twisting coil 5 is α. i The rotation direction of the i-th layer twisting head spool 5 is the same as the direction in which the i-th layer thread head needs to be twisted.

[0046] Specifically, step S2 involves moving one of the torsion head mold 1 and the stator assembly 2 toward the other, so that the free end of the lead wire 4 on the stator assembly 2 is inserted axially into the corresponding lead wire groove 6 in the corresponding torsion head coil 5, while keeping the welding wire 3 uninserted in the welding wire groove 7.

[0047] Specifically, step S4 involves moving one of the torsion head mold 1 and the stator assembly 2 toward the other, thereby inserting the free end of the welding wire head 3 in the stator assembly 2 into the corresponding welding wire groove 7 in the corresponding torsion head coil 5 along the axial direction, while simultaneously inserting the lead wire head 4 in the stator assembly 2 further into the corresponding lead wire groove 6 along the axial direction.

[0048] like Figure 7As shown, the method is implemented based on a head-turning machine. The head-turning mold 1 is installed in the head-turning machine, which is used to grasp the stator assembly 2 and drive the stator assembly 2 to move. The head-turning machine can drive the stator assembly 2 to align with the head-turning mold 1, and can drive each layer of head-turning coils 5 in the head-turning mold 1 to rotate independently. Furthermore, some head-turning machines can drive the head-turning mold 1 towards the stator assembly 2 in steps S2 and S4, while others can drive the stator assembly 2 towards the head-turning mold 1 in steps S2 and S4. The specific structure of the head-turning machine is prior art well known to those skilled in the art, and will not be described in detail in this embodiment. For example, a head-turning machine is disclosed in Chinese Patent Publication No. CN114337134B.

[0049] In this embodiment, the stator assembly 2 has eight layers of wire ends arranged sequentially from the inside out. The first layer of wire ends is located on the innermost side, the second layer of wire ends is located on the outer side of the first layer of wire ends, the third layer of wire ends is located on the outer side of the second layer of wire ends, and so on, with the eighth layer of wire ends located on the outermost side. Each layer of wire ends has a relatively long lead wire end 4 and a relatively short solder wire end 3.

[0050] In this embodiment, the twisting mold 1 includes eight layers of twisting coils 5 arranged sequentially from the inside out. The first layer of twisting coils 5 is located on the innermost side, the second layer of twisting coils 5 is located on the outer side of the first layer of twisting coils 5, the third layer of twisting coils 5 is located on the outer side of the second layer of twisting coils 5, and so on, with the eighth layer of twisting coils 5 located on the outermost side. The first layer of twisting coils 5 corresponds to the first layer of wire end, the second layer of twisting coils 5 corresponds to the second layer of wire end, and so on, with the eighth layer of twisting coils 5 corresponding to the eighth layer of wire end. Specifically, each layer of twisted wire reel 5 is provided with lead wire groove 6 and welding wire groove 7. The lead wire groove 6 in the first layer of twisted wire reel 5 corresponds one-to-one with the lead wire head 4 in the first layer of wire head, and the welding wire groove 7 in the first layer of twisted wire reel 5 corresponds one-to-one with the welding wire head 3 in the first layer of wire head. The lead wire groove 6 in the second layer of twisted wire reel 5 corresponds one-to-one with the lead wire head 4 in the second layer of wire head, and the welding wire groove 7 in the second layer of twisted wire reel 5 corresponds one-to-one with the welding wire head 3 in the second layer of wire head. And so on, the lead wire groove 6 in the eighth layer of twisted wire reel 5 corresponds one-to-one with the lead wire head 4 in the eighth layer of wire head, and the welding wire groove 7 in the eighth layer of twisted wire reel 5 corresponds one-to-one with the welding wire head 3 in the eighth layer of wire head. Furthermore, when the lead-out groove 6 in the i-th layer twisted wire spool 5 is aligned with the corresponding lead-out wire 4 in the i-th layer wire head, the welding groove 7 in the i-th layer twisted wire spool 5 will be misaligned with the corresponding welding wire 3 in the i-th layer wire head; where i = 1, 2, 3, 4, 5, 6, 7, 8.

[0051] In this embodiment, the specific operation of the head-turning method is as follows:

[0052] S1: Align the torsion head mold 1 with the stator assembly 2, rotate the first to eighth layers of torsion head coils 5, align the lead wire groove 6 in the first layer of torsion head coil 5 with the corresponding lead wire 4 in the first layer of wire head, align the lead wire groove 6 in the second layer of torsion head coil 5 with the corresponding lead wire 4 in the second layer of wire head, and so on, align the lead wire groove 6 in the eighth layer of torsion head coil 5 with the corresponding lead wire 4 in the eighth layer of wire head;

[0053] S2: Move the stator assembly 2 toward the twisting mold 1 so that the free end of the lead wire 4 in the first layer of the stator assembly 2 is inserted axially into the corresponding lead wire groove 6 in the first layer of the twisting coil 5, and so on, so that the free end of the lead wire 4 in the second layer of the stator assembly 2 is inserted axially into the corresponding lead wire groove 6 in the second layer of the twisting coil 5, and so on, until the free end of the lead wire 4 in the eighth layer of the stator assembly 2 is inserted axially into the corresponding lead wire groove 6 in the eighth layer of the twisting coil 5, while the welding wire 3 in the first to eighth layers of the stator assembly 2 remains uninserted into the welding wire groove 7.

[0054] S3: Rotate the first to eighth layer twisting coils 5 to align the welding groove 7 in the first layer twisting coil 5 with the corresponding welding wire head 3 in the first layer wire head, align the welding groove 7 in the second layer twisting coil 5 with the corresponding welding wire head 3 in the second layer wire head, and so on, aligning the welding groove 7 in the eighth layer twisting coil 5 with the corresponding welding wire head 3 in the eighth layer wire head. During this process, the lead wire heads 4 in the first to eighth layers wire heads will all be pre-twisted at a certain angle.

[0055] S4: Move the stator assembly 2 toward the twisting mold 1 again so that the free end of the welding wire head 3 in the first layer of wire head is inserted axially into the corresponding welding wire groove 7 in the first layer of twisting wire spool 5, and the free end of the welding wire head 3 in the second layer of wire head is inserted axially into the corresponding welding wire groove 7 in the second layer of twisting wire spool 5, and so on, so that the free end of the welding wire head 3 in the eighth layer of wire head is inserted axially into the corresponding welding wire groove 7 in the eighth layer of twisting wire spool 5. At this time, the lead wire head 4 will be inserted further into the corresponding lead wire groove 6.

[0056] S5: The first to eighth layer twisting coils 5 are rotated respectively, thereby causing the lead wire 4 inserted into the lead wire groove 6 and the welding wire 3 inserted into the welding wire groove 7 to be twisted and shaped.

[0057] Of course, in some embodiments, the torsion head mold 1 can also be moved toward the stator assembly 2 in steps S2 and S4.

[0058] In this embodiment, α1=α2=α3=α4=α5=α6=α7=α8=22.5°, β1=β2=β3=β4=β5=β6=β7=β8=20°. The ends of the first, third, fifth, and seventh layers of wires need to be twisted clockwise, and the ends of the second, fourth, sixth, and eighth layers of wires need to be twisted counterclockwise. Both clockwise and counterclockwise rotations are observed from top to bottom.

[0059] Because α1=α2=α3=α4=α5=α6=α7=α8>β1=β2=β3=β4=β5=β6=β7=β8, in step S3 of this embodiment, when rotating the first to eighth layer twisting coils 5, the rotation direction of the first layer twisting coil 5 is opposite to the direction that the first layer wire needs to be twisted; the rotation direction of the second layer twisting coil 5 is opposite to the direction that the second layer wire needs to be twisted; the rotation direction of the third layer twisting coil 5 is opposite to the direction that the third layer wire needs to be twisted; the rotation direction of the fourth layer twisting coil 5 is opposite to the direction that the fourth layer wire needs to be twisted; the rotation direction of the fifth layer twisting coil 5 is opposite to the direction that the fifth layer wire needs to be twisted; the rotation direction of the sixth layer twisting coil 5 is opposite to the direction that the sixth layer wire needs to be twisted; the rotation direction of the seventh layer twisting coil 5 is opposite to the direction that the seventh layer wire needs to be twisted; and the rotation direction of the eighth layer twisting coil 5 is opposite to the direction that the eighth layer wire needs to be twisted. Therefore, the rotation direction of the first, third, fifth, and seventh layer twisting coils 5 in step S3 is counterclockwise, and the rotation direction of the second, fourth, sixth, and eighth layer twisting coils 5 in step S3 is clockwise. The rotation angle of the first to eighth layer twisting coils 5 in step S3 is 2.5°.

[0060] In step S5 of this embodiment, when the first to eighth layer twisting coils 5 are rotated respectively, the rotation direction of the first layer twisting coil 5 is the same as the direction in which the first layer of thread needs to be twisted; the rotation direction of the second layer twisting coil 5 is the same as the direction in which the second layer of thread needs to be twisted; the rotation direction of the third layer twisting coil 5 is the same as the direction in which the third layer of thread needs to be twisted; the rotation direction of the fourth layer twisting coil 5 is the same as the direction in which the fourth layer of thread needs to be twisted; the rotation direction of the fifth layer twisting coil 5 is the same as the direction in which the fifth layer of thread needs to be twisted; and the rotation direction of the sixth layer twisting coil 5... The rotation direction of the coil 5 is the same as the direction in which the sixth layer of thread needs to be twisted, the rotation direction of the seventh layer coil 5 is the same as the direction in which the seventh layer of thread needs to be twisted, and the rotation direction of the eighth layer coil 5 is the same as the direction in which the eighth layer of thread needs to be twisted. Therefore, the rotation direction of the first, third, fifth, and seventh layer coils 5 in step S5 is clockwise, and the rotation direction of the second, fourth, sixth, and eighth layer coils 5 in step S5 is counterclockwise. The rotation angle of the first to eighth layer coils 5 in step S5 is 22.5°.

[0061] In summary, step S1 aligns the lead-out slots 6 in each layer of the twisting coil 5 with the corresponding lead-out ends 4 in the corresponding layer of the wire head. At this time, the welding slots 7 in each layer of the twisting coil 5 are misaligned with the corresponding welding ends 3 in the corresponding layer of the wire head. Since the lead-out end 4 is longer than the welding end 3, step S2 allows the free end of the lead-out end 4 in the stator assembly 2 to be inserted into the corresponding lead-out slot 6 in the corresponding twisting coil 5, while the welding end 3 in the stator assembly 2 is not inserted into the welding slot 7. After step S3, the lead wire 4 inserted into the lead wire groove 6 will be pre-twisted by the twisting coil 5 at a certain angle. The welding wire 3, because it is not inserted into the welding wire groove 7, is not pre-twisted. In step S3, the welding wire groove 7 in each layer of twisting coil 5 is aligned with the corresponding welding wire 3 in the corresponding layer of wire. Then, in step S4, the free end of the welding wire 3 in the stator assembly 2 can be inserted axially into the corresponding welding wire groove 7 in the corresponding twisting coil 5. During the process of the welding wire 3 being inserted axially into the welding wire groove 7, the lead wire 4 will be inserted deeper into the corresponding lead wire groove 6. Then, in step S5, by rotating each layer of twisting coil 5, the lead wire 4 inserted into the lead wire groove 6 and the welding wire 3 inserted into the welding wire groove 7 can be twisted to form the desired angle. In step S3, the lead wire 4 in the same layer is pre-twisted by a certain angle while the welding wire 3 is not pre-twisted. In step S5, the lead wire 4 and the welding wire 3 in the same layer are both twisted by the same angle, thus achieving the purpose of twisting the lead wire 4 and the welding wire 3 in the same layer of the stator assembly 2 by different angles.

[0062] The specific embodiments described above further illustrate the technical problems, technical solutions, and beneficial effects of the present invention. It should be understood that the above descriptions are merely specific embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for twisting stator assemblies for new energy vehicles with different twist angles at the same layer of wire ends, characterized in that, The method is implemented based on a torsion mold (1) and used to torsion the stator assembly (2); The stator assembly (2) has N layers of wire ends arranged sequentially from the inside to the outside. Each layer of wire ends has a welding wire end (3) and a lead wire end (4). The lead wire end (4) is longer than the welding wire end (3), where N≥2. The twisting head mold (1) includes N layers of twisting head coils (5) arranged sequentially from the inside to the outside. The N layers of twisting head coils (5) correspond one-to-one with the N layers of wire ends in the stator assembly (2). The twisting head coil (5) is provided with lead wire grooves (6) corresponding to the lead wire ends (4) in the corresponding layer of wire ends. The twisting head coil (5) is also provided with welding wire grooves (7) corresponding to the welding wire ends (3) in the corresponding layer of wire ends. When the lead wire grooves (6) in the twisting head coil (5) are aligned with the corresponding lead wire ends (4) in the corresponding layer of wire ends in the stator assembly (2), the welding wire grooves (7) in the twisting head coil (5) are misaligned with the corresponding welding wire ends (3) in the corresponding layer of wire ends. The steps of the method include: S1: Align the torsion head mold (1) with the stator assembly (2), rotate each layer of torsion head coil (5) in the torsion head mold (1) so that the lead wire groove (6) in each layer of torsion head coil (5) is aligned with the corresponding lead wire head (4) in the corresponding layer of wire head in the stator assembly (2). At this time, the welding wire groove (7) in each layer of torsion head coil (5) is misaligned with the corresponding welding wire head (3) in the corresponding layer of wire head in the stator assembly (2). S2: Insert the free end of the lead wire (4) into the corresponding lead wire groove (6) in the corresponding twist head coil (5) along the axial direction, and keep the welding wire (3) out of the welding groove (7); S3: Rotate each layer of twisting head coil (5) to align the welding wire groove (7) in each layer of twisting head coil (5) with the corresponding welding wire head (3) in the corresponding layer of wire head. At this time, the lead wire head (4) inserted into the lead wire groove (6) is pre-twisted by the twisting head coil (5) at a certain angle. S4: Insert the free end of the welding wire head (3) in the stator assembly (2) into the corresponding welding wire groove (7) in the corresponding twist head coil (5) along the axial direction. At this time, the lead wire head (4) will be further inserted into the corresponding lead wire groove (6). S5: Make each layer of twisting head coil (5) rotate in the direction that the corresponding layer of wire head needs to be twisted, thereby driving the lead wire head (4) inserted into the lead wire groove (6) and the welding wire head (3) inserted into the welding wire groove (7) to twist and form the angle.

2. The torsion method for stator assemblies of new energy vehicles with different torsion angles at the same layer of wire ends according to claim 1, characterized in that, The i-th layer of twisting coil (5) in the twisting mold (1) corresponds to the i-th layer of wire head in the stator assembly (2); wherein, the i-th layer of twisting coil (5) and the i-th layer of wire head are both the i-th layer from the inside out, i is an integer, 1≤i≤N; In step S3, when rotating each layer of twisting coil (5) to align the welding groove (7) in each layer of twisting coil (5) with the corresponding welding head (3) in the corresponding layer of wire head, the rotation angle of the i-th layer twisting coil (5) is |α. i -β i |, if α i >β i Then the rotation direction of the i-th layer twisting coil (5) is opposite to the direction that the i-th layer thread head needs to be twisted. If α i <β i Then the rotation direction of the i-th layer twisting coil (5) is the same as the direction that the i-th layer thread head needs to be twisted; Where, α i The angle β is the angle that the solder joint (3) in the i-th layer needs to be twisted. i The angle that the lead wire (4) in the i-th layer of the wire needs to be twisted is the same as the direction that the lead wire (4) and the solder wire (3) in the same layer of the wire need to be twisted.

3. The torsion method for stator assemblies of new energy vehicles with different torsion angles at the same layer of wire ends according to claim 2, characterized in that, In step S5, when the twisting coils (5) of each layer rotate in the direction that the corresponding layer wire ends need to be twisted, thereby causing the lead wire ends (4) inserted into the lead wire groove (6) and the welding wire ends (3) inserted into the welding wire groove (7) to be twisted at the desired angle, the rotation angle of the i-th layer twisting coil (5) is α. i The rotation direction of the i-th layer twisting head coil (5) is the same as the direction in which the i-th layer thread head needs to be twisted.

4. The method for twisting stator assemblies for new energy vehicles with different twist angles at the same layer of wire ends according to claim 1, characterized in that, The specific operation of step S2 is as follows: move one of the twisting head mold (1) and the stator assembly (2) toward the other of the twisting head mold (1) and the stator assembly (2) so that the free end of the lead wire head (4) on the stator assembly (2) is inserted axially into the corresponding lead wire groove (6) in the corresponding twisting head coil (5), and keep the welding wire head (3) uninserted into the welding wire groove (7).

5. The method for twisting stator assemblies for new energy vehicles with different twist angles at the same layer of wire ends according to claim 1, characterized in that, The specific operation of step S4 is as follows: move one of the twisting head mold (1) and the stator assembly (2) toward the other of the twisting head mold (1) and the stator assembly (2), thereby inserting the free end of the welding wire head (3) in the stator assembly (2) into the corresponding welding wire groove (7) in the corresponding twisting head coil (5) along the axial direction, and at the same time, inserting the lead wire head (4) in the stator assembly (2) further into the corresponding lead wire groove (6) along the axial direction.

6. The method for twisting stator assemblies for new energy vehicles with different twist angles at the same layer of wire ends according to claim 1, characterized in that, The method is implemented based on a head-turning machine, wherein the head-turning mold (1) is installed in the head-turning machine, and the head-turning machine is used to grab the stator assembly (2) and drive the stator assembly (2) to move.

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