A guide needle type winding device and winding method for an ultra-thin micro brushless motor stator

Abstract

The application discloses a guide needle type winding equipment and winding method for an ultra-thin micro brushless motor stator. The guide needle is used to guide the enameled wire to pass through the tooth gap on both sides of the stator tooth to form a coil, and the wire falling position is defined by the wire arranging part on the axial end face side. Before forming the next coil, the winding state detection assembly is used to obtain the actual wire falling position of the formed coil and the winding top height of the corresponding position. According to the detection result, the current winding occupation state, the reference wire falling position, the first correction wire falling position and the second correction wire falling position are determined, the assumed winding occupation state is established respectively, the subsequent wire arranging position sequence is determined according to the winding sequence of the remaining coils, the wire falling position which cannot complete the winding of the remaining coils is excluded according to the allowable winding end height, the target wire falling position is determined from the feasible wire falling position, and the wire arranging part is controlled to complete the wire laying. The application can reduce the possibility that the local winding end exceeds the allowable height and improve the end face space utilization degree.

Description

Technical Field

[0001] This invention relates to the field of motor stator winding equipment technology, and in particular to a guide pin type winding equipment and winding method for ultra-thin micro brushless motor stators. Background Technology

[0002] The axial dimension of the stator of the ultra-thin micro brushless motor is small, and the space between the stator teeth is limited. When multiple turns of enameled wire are continuously wound on the stator teeth, the enameled wire needs to repeatedly pass through the two axial end faces of the stator teeth. For micro brushless motors with limited axial installation space, the highest local position at the winding end will directly occupy the axial space inside the motor and may affect the assembly of adjacent rotors, drive circuit boards or other components.

[0003] For the 3-slot or 6-slot miniature stator used in external rotor brushless motors, the stator outer diameter is only about 6.4 mm, and the insulating frame also needs to be arranged with the wiring pins for winding lead-out. Under such miniature size, the binding wire, soldering space at the beginning and end of the winding, as well as the final lead-out position of the wiring pins are all restricted. If the wiring pins are in the final bent state before winding, they may also occupy the space required for guide pins, wire guides, or binding wire operations. In order to limit the range of motion of the enameled wire, some equipment will also set wire baffles, wire supports, or other limiting structures at the stator end face to prevent the enameled wire from deviating from the winding area and to a certain extent constrain the overall shape of the winding. However, the above-mentioned wiring method mainly considers the arrangement relationship between the current coil or adjacent coils. When the available space on the stator tooth end face is limited by local height, or when the coils that have already been formed cause changes in the remaining winding space at different positions, continuing to form subsequent coils according to the wiring result may cause some available wiring areas to be occupied in advance, causing the remaining coils to concentrate in other areas, thus resulting in local stacking of subsequent coils. Especially when different areas on the stator tooth end face have different allowable winding end heights, determining the amount of movement between adjacent wiring positions only based on the outer diameter of the enameled wire, or only changing layers when the current wiring position cannot continue to be wound, makes it difficult to simultaneously consider the impact of the current coil falling on the remaining coil arrangement space.

[0004] It is necessary to determine the current winding occupancy status based on the already formed turns, while maintaining the suitability of the guide pin winding method for the narrow space between the teeth of the miniature stator. This involves judging the subsequent winding status when the next turn is placed at different drop positions, so that the drop position of the current turn not only meets the current winding requirements, but also reserves winding space for the remaining turns to meet the corresponding height restrictions. Summary of the Invention

[0005] This invention overcomes the shortcomings of the prior art and provides a guide pin winding device and winding method for the stator of an ultra-thin micro brushless motor.

[0006] To achieve the above objectives, the technical solution adopted by this invention is as follows: a guide pin winding method for the stator of an ultra-thin micro brushless motor, comprising the following steps: S1, guide the enameled wire through the gap between the teeth on both sides of the stator tooth to be wound to form a wire turn, take the most recently formed wire turn as the current wire turn, and determine the current winding occupancy status according to the falling position of the already formed wire turn and the top height of the winding before forming the next wire turn. S2, determine the reference drop position of the next turn based on the current winding occupancy status, and determine the first corrected drop position and the second corrected drop position on the two sides of the reference drop position facing and away from the current turn, respectively. S3, respectively assume that the next winding is formed at the reference drop position, the first corrected drop position and the second corrected drop position, and obtain the corresponding assumed winding occupancy state according to the winding occupancy range and the top height of the winding corresponding to each drop position. S4. Starting from the assumed winding occupancy status, determine the wiring position of the subsequent windings in sequence according to the winding order of the remaining windings, and determine whether the remaining windings can be wound according to the allowable winding end height at the corresponding position, thus forming the corresponding sequence of subsequent wiring positions. S5, eliminate the drop positions that cannot complete the remaining wire turns, and determine the target drop position from the drop positions that can complete the remaining wire turns. S6, control the cable tray to move to the cable tray position corresponding to the target drop position, and when the guide needle is releasing the wire from the end face, the cable tray limits the formation of the enameled wire at the target drop position.

[0007] In a preferred embodiment of the present invention, the available wiring area of ​​the stator tooth end face to be wound is divided into a first wiring area, a second wiring area and a third wiring area along the wiring direction. The first wiring area, the second wiring area and the third wiring area correspond to the first allowable winding end height, the second allowable winding end height and the third allowable winding end height, respectively. The second allowable winding end height is greater than the first allowable winding end height and the third allowable winding end height. When determining the subsequent wiring sequence, the wiring position of the turn is judged to see if it meets the winding conditions based on the allowable winding end height corresponding to the wiring area where the turn is located.

[0008] In a preferred embodiment of the present invention, a reference falling position is determined based on the current falling position of the coil and the reference wiring movement; the first corrected falling position is located on the side of the reference falling position facing the current falling position of the coil, and the second corrected falling position is located on the side of the reference falling position away from the current falling position of the coil; the subsequent wiring position sequence is determined in the order of the reference falling position, the first corrected falling position, and the second corrected falling position.

[0009] In a preferred embodiment of the present invention, the reference cable movement amount is determined based on the outer diameter of the enameled wire and the cable correction coefficient; The wiring correction coefficient is determined by trial winding of stators and enameled wires of the same specifications; during the trial winding process, the actual center position of adjacent turns is obtained, and the wiring correction coefficient is adjusted according to the deviation between the actual center distance of adjacent turns and the preset target center distance until the absolute value of the deviation is not greater than the preset distance tolerance.

[0010] In a preferred embodiment of the present invention, the current winding occupancy state further includes the current winding layer and the current wiring direction; it is first assumed that the next turn is formed at the reference drop position, and the wiring position of the subsequent turns is determined sequentially according to the winding order of the remaining turns; When the subsequent wiring position sequence formed by the reference falling position cannot complete the remaining wire turns, the subsequent wiring position sequence is determined sequentially for the first corrected falling position and the second corrected falling position. When the subsequent wiring sequence corresponding to the reference falling position, the first corrected falling position, and the second corrected falling position cannot complete the remaining wire turns, the wiring of the current winding layer ends, the next wire turn enters the next winding layer, and the wiring component moves in the opposite direction to the current wiring direction.

[0011] A guide pin type winding device for the stator of an ultra-thin micro brushless motor includes a stator clamp, a stator drive mechanism, a guide pin assembly, a guide pin drive mechanism, a wire assembly, a wire drive mechanism, a winding status detection assembly, and a control device. The stator clamp is connected to the stator drive mechanism and is used to position the stator to be wound and drive the stator to be wound to rotate. The guide pin assembly includes a guide pin through which the enameled wire passes, and the guide pin driving mechanism drives the guide pin to pass through the tooth gap on both sides of the stator tooth to be wound along the axial direction of the stator to be wound. The wiring assembly includes a wiring component disposed on the first axial end face side of the stator to be wound, and the wiring drive mechanism drives the wiring component to move along the wiring direction of the stator tooth end face to be wound. The control device is connected to the stator drive mechanism, the guide pin drive mechanism and the wire laying drive mechanism respectively. The control device determines the current winding occupancy status based on the falling position of the formed coil and the top height of the winding, determines the reference falling position, the first corrected falling position and the second corrected falling position of the next coil, and determines the target falling position so that the remaining coil can be wound according to the allowable winding end height by establishing the assumed winding occupancy status corresponding to the three falling positions respectively, and controls the wire laying component to move to the wire laying position corresponding to the target falling position.

[0012] In a preferred embodiment of the present invention, during the process of forming a turn of wire, the wire guide has a working position close to the end face of the stator tooth to be wound and a clearance position that avoids the movement path of the guide pin, and the wire guide drive mechanism drives the wire guide to move between the working position and the clearance position. The wiring component forms a guide needle avoidance part for the guide needle to pass through and a wiring part for limiting the position of the enameled wire drop. The wiring part is located on the side of the guide needle avoidance part facing the wiring direction, and is located in a restricted position corresponding to the target drop position when the guide needle is releasing the wire from the end face.

[0013] A surface-mount ultrathin micro brushless motor stator assembly includes a stator core, an insulating frame disposed on the stator core, a winding wound on the stator core, and multiple wiring pins. The outer diameter of the stator core is less than 6.5 mm, and the insulating frame is provided with a pin retaining structure for fixing the wiring pins; The plurality of wiring pins are electrically connected to the starting end and / or ending end of the winding, respectively. The wiring pins include a fixing part connected to the insulating frame and a bendable lead-out part extending from the fixing part. The bendable lead-out part is bent and shaped to form a mounting part. The plurality of mounting parts are located on the same mounting side of the stator assembly and respectively form a soldering surface for connecting to the corresponding pad of the flexible circuit board. At least a portion of the winding is provided with a high-temperature resistant curing material to restrict the displacement of the turns in the winding relative to the stator core and / or the insulating frame, so that the stator assembly can be mounted on a flexible circuit board as a surface mount device.

[0014] In a preferred embodiment of the present invention, the stator assembly further includes a high-temperature resistant encapsulation covering the outside of the insulating frame and / or windings, the high-temperature resistant encapsulation being formed of a liquid crystal polymer (LCP) material.

[0015] In a preferred embodiment of the present invention, the high-temperature resistant curing material includes a high-temperature resistant UV curing adhesive, which is disposed at least between adjacent turns and / or between the winding and the insulating frame.

[0016] This invention addresses the shortcomings of the prior art and has the following beneficial effects: This invention provides a wire-laying component on the axial end face of the stator to be wound. Before forming the next turn, the actual drop position and top height of the already formed turns are obtained through a winding state detection component, and the current winding occupancy status is determined. Based on the reference drop position, a first corrected drop position and a second corrected drop position are further determined. By assuming that the next turn is formed at different drop positions, the corresponding assumed winding occupancy status is obtained, and the subsequent wire-laying positions are determined according to the winding sequence of the remaining turns. Before the current turn is actually formed, the impact of different drop positions on the subsequent winding process is judged. Compared with the method of directly determining the position of the next turn based solely on the winding progress, the outer diameter of the enameled wire, or a pre-set wire-laying trajectory, this invention judges whether the remaining turns can be wound according to the allowable winding end height of the corresponding position after adopting the drop position, and eliminates drop positions that would prevent the subsequent turns from meeting the winding conditions. This ensures that the determination of the current drop position takes into account both the already formed winding state and the winding requirements of the remaining turns, improving the rationality of the utilization of winding end space and the consistency of different stator winding shapes.

[0017] This invention divides the available wire-laying area on the end face of the stator teeth to be wound into multiple wire-laying areas corresponding to different allowable winding end heights. When determining the subsequent wire-laying position sequence, it judges whether the wire-laying position meets the winding conditions based on the allowable winding end height of the corresponding turn's wire-laying area. This makes the wire-laying control not only limited by the end face plane range but also combined with the axial space actually used at different positions. At the same time, the reference wire-dropping position is determined based on the wire-laying position corresponding to the current turn and the reference wire-laying movement amount, and a first corrected wire-dropping position and a second corrected wire-dropping position are set on both sides of the reference wire-dropping position. Positioning prioritizes maintaining the adjacent winding relationship formed by the reference movement under normal winding conditions. When the subsequent winding result corresponding to the reference placement position cannot meet the winding conditions of the remaining turns, the subsequent winding occupancy state is changed by correcting the placement position. When none of the candidate placement positions in the current winding layer can enable the remaining turns to continue winding, the current winding layer is terminated and the winding direction of the next winding layer is changed, forming a winding method that combines reference winding, position correction, and layer-changing winding. This improves the adaptability to changes in the actual winding state while maintaining a close arrangement of adjacent turns.

[0018] This invention sets allowable winding end heights at corresponding positions on the first and second axial end faces of the stator teeth to be wound, and determines corresponding target drop positions based on the existing coils on each of the two axial end faces. This allows the same coil to be laid out according to the remaining winding space and allowable winding end height of the corresponding end faces when passing through the two axial end faces. The laying component includes a guide needle clearance part for the guide needle to pass through and a laying part for limiting the enameled wire drop position. This allows the guide needle to perform axial slotting movement within the narrow tooth gap, and during the end face laying stage, the laying part near the exit position restricts the enameled wire from crossing the currently determined target drop position. After the guide needle exits the tooth gap, the exit port faces the current target drop position. The target drop position determined based on the winding occupancy status and allowable winding end height is converted into the actual end face drop position of the enameled wire. Without adding a complex laying mechanism to the narrow tooth gap area, this invention achieves coordination between the judgment of the remaining coil winding status and the guide needle winding mechanical action, improving the stability of stator winding end height control in ultra-thin micro brushless motors.

[0019] In the implementation of the miniature external rotor stator, the wiring pin is fixed as an insert during the injection molding of the insulating skeleton, so that the wiring pin remains stable during the winding process. By setting a binding position at the opening of the wiring pin, the starting end and the ending end of the winding of the enameled wire can be positioned in a limited space. After tinning, the wiring pin is bent, so that a large operating space is reserved in the winding, binding and tinning stages. At the same time, the bent wiring pin adapts to the compact space required for subsequent electrical connection and overall assembly.

[0020] This invention designs the stator assembly of a miniature brushless motor as a surface mount structure. By shaping the bendable lead-out portion of the wiring pins into a mounting portion and placing multiple mounting portions on the same mounting side, the stator assembly can be directly connected to the corresponding pads of the flexible circuit board. At the same time, by fixing the windings with a high-temperature resistant curing material, the possibility of displacement between the turns of the miniature windings and between the windings and the insulation structure is reduced, enabling the stator assembly to adapt to subsequent surface mount processes and improving the integration level of the miniature motor assembly. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Figure 1 This is a flowchart of the guide pin winding method for the stator of an ultra-thin micro brushless motor according to the present invention; Figure 2This is a three-dimensional structural diagram of the guide pin type winding device for the stator of an ultra-thin micro brushless motor according to the present invention; Figure 3 yes Figure 2 Enlarged view of point A in the middle; Figure 4 This is a schematic diagram of the structure before the stator bend is wound in this invention; Figure 5 This is a schematic diagram of the structure after the stator bend is wound in this invention; In the diagram: 1. Frame; 2. Stator clamp; 3. Stator to be wound; 31. Stator core; 32. Insulating frame; 33. Wiring pin; 4. Stator drive mechanism; 5. Guide pin assembly; 51. Guide pin; 52. Wire passage; 6. Guide pin drive mechanism; 7. Wire laying assembly; 71. Upper wire laying assembly; 72. Lower wire laying assembly; 73. Wire laying section; 74. Guide pin clearance section; 8. Wire laying drive mechanism; 9. Control device. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention is also practiced in other ways different from those described herein, and the scope of protection of the invention is not limited to the specific embodiments disclosed below.

[0024] This invention is mainly applied to the concentrated winding of stators in ultra-thin micro brushless motors, and is especially suitable for scenarios where the stator axial space is small, the stator tooth gap is narrow, and fine enameled wire is used for winding. When multiple turns of winding need to be continuously formed for the same stator tooth to be wound, and the end face of the stator tooth to be wound is restricted by the rotor, drive circuit board, insulating frame, wiring structure or internal structure of the housing, the allowable winding end height at each position is not exactly the same. This invention controls the wire drop position of the turn end face and uses the allowable winding end height at different positions as a criterion for judging whether subsequent winding can be completed.

[0025] Example 1: As Figure 4 and Figure 5As shown, this embodiment provides a surface-mount ultra-thin micro brushless motor stator assembly, including a stator core 31, an insulating frame 32, windings, and multiple terminal pins 33. The stator core 31 is formed by stacking multiple silicon steel sheets axially, and the outer diameter of the stator core is less than 6.5 mm. This embodiment uses a 3-slot stator core as an example, with axially continuous tooth gaps formed between adjacent stator teeth; in other embodiments, a 6-slot stator core can also be used. In one specific embodiment, the outer diameter of the stator core is approximately 6.4 mm, and 0.05–0.07 mm enameled wire is used to form concentrated windings on each stator tooth.

[0026] An insulating frame 32 is disposed on the stator core 31, and a pin retaining structure is formed on at least one axial end face of the stator core. A plurality of wiring pins 33 are positioned relative to the stator core 31 by means of the pin retaining structure. The exposed portion of the wiring pins 33 includes a wire binding portion with an opening and a bendable lead-out portion connected to the wire binding portion. Each connector pin 33 includes a wire-binding portion with an opening and a bendable lead-out portion. After the winding is completed and the winding end is electrically connected to the connector pin 33, the bendable lead-out portion of the connector pin 33 is bent and shaped to change it from a winding state to a mounting state. In the mounting state, the bendable lead-out portion of each connector pin 33 forms a mounting portion. The mounting portion is used to connect to the corresponding pad on the flexible circuit board through a reflow soldering process. Multiple mounting portions are located on the same side of the stator assembly and form a soldering surface facing the pad on the flexible circuit board, so that the stator assembly can be electrically connected to the flexible circuit board through the mounting portion without the need for an additional adapter structure.

[0027] After the winding is formed, a high-temperature resistant curing material is applied to at least a portion of the winding. This material is positioned between adjacent turns or between the winding and the insulating frame, and the resulting fixed structure restricts relative movement between the turns and between the winding and the insulating frame. In one embodiment, the high-temperature resistant curing material is a high-temperature UV-curable adhesive, which is cured by ultraviolet light irradiation, maintaining a stable winding shape. After the winding is fixed, the stator assembly is encapsulated in a high-temperature resistant manner. The encapsulated body covers the insulating frame and / or the outside of the winding, improving the overall mechanical strength and environmental adaptability of the stator assembly. In one embodiment, the encapsulated body is formed using a liquid crystal polymer material, giving the encapsulated stator assembly good dimensional stability and high-temperature resistance, adapting to the thermal environment during subsequent surface mounting processes.

[0028] like Figure 1 As shown, a guide pin winding method for the stator of an ultra-thin micro brushless motor includes the following steps: S1, guide the enameled wire through the gap between the teeth on both sides of the stator tooth to be wound to form a wire turn, take the most recently formed wire turn as the current wire turn, and determine the current winding occupancy status according to the falling position of the already formed wire turn and the top height of the winding before forming the next wire turn. S2, determine the reference drop position of the next turn based on the current winding occupancy status, and determine the first corrected drop position and the second corrected drop position on the two sides of the reference drop position facing and away from the current turn, respectively. S3, respectively assume that the next winding is formed at the reference drop position, the first corrected drop position and the second corrected drop position, and obtain the corresponding assumed winding occupancy state according to the winding occupancy range and the top height of the winding corresponding to each drop position. S4. Starting from the assumed winding occupancy status, determine the wiring position of the subsequent windings in sequence according to the winding order of the remaining windings, and determine whether the remaining windings can be wound according to the allowable winding end height at the corresponding position, thus forming the corresponding sequence of subsequent wiring positions. S5, eliminate the drop positions that cannot complete the remaining wire turns, and determine the target drop position from the drop positions that can complete the remaining wire turns. S6, control the cable tray to move to the cable tray position corresponding to the target drop position, and when the guide needle is releasing the wire from the end face, the cable tray limits the formation of the enameled wire at the target drop position.

[0029] Before the first turn of the corresponding winding is wound, the enameled wire led out from the guide pin outlet is led to the connecting pin corresponding to the current winding, so that the starting end of the winding of the enameled wire enters the opening of the binding part and is wound or hooked and fixed in the binding part to form the starting binding position of the winding; after the starting end of the winding is positioned, the guide pin performs the subsequent slotting and end face wire release actions.

[0030] Before the current stator tooth to be wound begins, the total number of turns N is determined according to the product winding design, and constraint parameters corresponding to the current product are established. Simultaneously, the current winding occupancy status is initialized. Initialization includes setting the completed number of turns n to 0, setting the current winding layer as the first winding layer, setting the current wiring direction to the preset initial wiring direction, and setting the current winding top height of each occupancy unit to the corresponding height reference value. The control device controls the wiring component to complete the first turn according to the preset initial drop position. After the first turn is formed, the winding status detection component obtains its actual drop position and the corresponding winding top height and updates the current winding occupancy status. Starting from the second turn, after each turn is completed, the current winding occupancy status is updated based on the detected actual drop position and the top height of the winding. After the nth turn is completed, the nth turn is taken as the current turn, and the (n+1)th turn is taken as the current turn to be formed. Based on the current winding occupancy status, multiple candidate drop positions corresponding to the (n+1)th turn are determined, and each candidate drop position is taken as the assumed drop position of the (n+1)th turn. The placement positions of the remaining unwound turns are deduced, and based on the deduction results, it is determined whether the remaining turns corresponding to each candidate drop position can be wound. The target drop position is determined from the candidate drop positions that meet the winding conditions. After the (n+1)th turn is actually laid out according to the target drop position, the current winding occupancy status is updated based on the detection results of the winding status detection component, and the winding of the next turn begins. The remaining turns are the turns from the (n+1)th turn to the Nth turn that have not yet been actually formed.

[0031] Example 2: Specifically, in step S1, before forming the next turn, the current winding occupancy status is determined, and the enameled wire already wound on the end face of the stator tooth to be wound is converted into occupancy data calculated by the control device, so that the control device can determine which positions on the end face have been occupied by the wire turns, how high the winding has been formed at each position, which turn has been wound to the current position, and which winding layer it is currently in.

[0032] The current winding occupancy status includes the drop position of the formed turns, the current winding top height at the corresponding position, the number of completed turns, the current winding layer, and the current wiring direction. The drop position is the position where the enameled wire forms the end face wire after being restricted by the wiring component on the axial end face of the stator tooth to be wound. The wiring direction is the direction in which adjacent turns are arranged sequentially within the same winding layer. The current winding top height is the distance from the unified height reference plane to the outermost surface of the existing winding at the corresponding position. The number of completed turns is the number of complete turns that have actually been formed on the stator tooth to be wound. The current winding layer indicates the stacking level of the current turns relative to the end face of the stator tooth to be wound.

[0033] Establish a one-dimensional position coordinate x along the winding direction of the stator tooth end face, and divide the available winding area for arranging the winding ends into m consecutive occupied units. The width of each occupied unit is b, and the j-th occupied unit stores the current top height h of the winding. j The allowable winding end height H corresponding to the occupied unit j The occupancy unit is used to discretize a continuous end-face region into a physical region that is updated position by position.

[0034] In step S1, the winding status detection component performs online detection on the axial end face of the stator tooth to be wound after each turn of wire is formed and stabilized. The position detection unit uses an industrial camera to acquire end face images containing the available wire laying area. The control device identifies the center position of each formed turn of wire according to the pre-established calibration relationship between the image coordinates and the position coordinate x, and obtains the actual wire laying center position. The height detection unit uses a laser contour sensor, the detection range covers the available wire laying area, and outputs the winding surface contour along the wire laying direction. The control device obtains the height of the outermost surface of the winding in each occupied unit based on a unified height reference plane. The detection results of the position detection unit and the height detection unit are transmitted to the control device and associated with the corresponding turn number for storage.

[0035] When determining the current winding occupancy status, the control device reads the actual drop position of the formed coil and the corresponding winding top height output by the winding status detection component. For each formed coil, the occupancy unit it covers is determined according to the actual drop center position of the coil and the effective occupancy width of the enameled wire. These occupancy units are recorded as the occupancy range of the coil, and the current winding top height of the corresponding occupancy unit is updated according to the winding top height detected by the height detection unit.

[0036] For a newly formed turn of wire, let the position of its center of fall be x. q The effective width d occupied by the enameled wire e The set of occupied units covered by this coil is determined by the interval of the coil in the cabling direction, and the interval is... Take the existing h from all occupied cells covered by this interval. j The maximum value is taken as the support height h of the coil. s The calculated top height h after the new turn is formed new =h s +h e And update the height of the occupied cell covered by the coil to h. new When a new winding is placed on an existing local protrusion, the actual higher support position is used as the starting point for the height, so as to avoid underestimating the height of the local winding end simply by multiplying the number of winding layers by the outer diameter of the enameled wire.

[0037] The occupancy unit width b is used to determine the spatial resolution of the winding occupancy status. In this embodiment, b is taken as the outer diameter d of the enameled wire including the enamel film. Effective width d e and effective floor height h e Using the outer diameter d of the enameled wire including the enamel film as the initial value, and correcting it through trial winding results of a stator of the same specification and an enameled wire of the same specification, d e h reflects the actual width occupied by the enameled wire along the wire laying direction under winding tension and end-face attachment conditions. e This reflects the actual increase in the top height of the winding after adding an additional layer of coils.

[0038] As a feasible parameter calibration method, at least three independent trial windings are performed. Each time, under the same stator specifications, enameled wire specifications, and winding tension conditions, at least ten adjacent turns are continuously formed. The total coverage width of the formed turns in the winding direction and the change in the top height of the winding are measured. The total coverage width divided by the number of turns involved in the measurement yields d. e The initial measured value, h is obtained by the difference in top height before and after adding a winding layer at the same position. e The measured values ​​and the arithmetic mean of the results obtained from multiple trial windings are used as the product formula parameters.

[0039] The selected data—the drop position, current top height of the winding, number of completed turns, current winding layer, and current wiring direction—correspond to the lateral occupancy, axial occupancy, remaining winding quantity, stacking relationship, and subsequent arrangement direction of the winding on the end face, respectively. Together, these data determine the actual impact of the next turn's formation on the remaining wiring space. By simultaneously recording the position and height, subsequent calculations identify the remaining capacity of different local areas under the same total winding height, establishing a correspondence between the current winding occupancy status and the actual space occupancy of the stator end face to be wound.

[0040] Step S2: Determine the baseline drop position, the first corrected drop position, and the second corrected drop position based on the current winding occupancy status; calculate the position where the next turn should normally fall according to the normal adjacent winding pitch; then set a small range of corrected positions on the side closer to the current turn and the side farther away from the current turn at that position to obtain three candidate drop positions for subsequent comparison.

[0041] The reference placement position is the next normal wiring position obtained sequentially from the placement position of the current turn according to the current wiring direction and the reference wiring movement amount; the first corrected placement position is located on the side of the reference placement position facing the current turn, and is used to appropriately reduce the wiring spacing when the normal wiring position is not conducive to the subsequent space utilization; the second corrected placement position is located on the side of the reference placement position away from the current turn, and is used to appropriately increase the wiring spacing when the normal wiring position is not conducive to the subsequent space utilization; the reference placement position, the first corrected placement position, and the second corrected placement position together constitute the candidate placement position set of the current turn to be formed.

[0042] Let x be the actual center position of the current turn. c The current cabling direction is represented by the direction quantity s. When cabling increases along the position coordinate x, s=1; when cabling decreases along the position coordinate x, s=-1. The reference cabling movement is denoted as Δx, and the reference landing position is x. b according to Determine; let the correction amount be δ, and the first correction line position be x. a according to Confirmed, second corrected landing position x z according to Confirmed. c , Δx, δ, x b x a and x z All units are mm.

[0043] The baseline cable movement Δx is determined based on the outer diameter d of the enameled wire including the enamel film and the cable correction factor k, Δx = Where d is in mm and k is a dimensionless coefficient; the theoretical center-to-center distance between adjacent turns in the same winding layer is mainly limited by the actual outer diameter of the enameled wire, so the outer diameter d of the enameled wire including the enamel film is selected as the reference. The wiring correction coefficient k is used to compensate for the actual wiring spacing changes caused by the enamel film thickness deviation, winding tension, end face springback and the position of the wiring component.

[0044] The wire winding correction factor k was obtained through trial winding of products of the same specification, with an initial value of 1. Under the conditions that the guide pin stroke, the relative rotation position of the stator to be wound, and the winding tension remain stable, at least ten adjacent turns are continuously formed, and the actual center position x of each turn is obtained using the position detection unit. i And calculate the actual center distance p based on the actual center position of the adjacent turns. i =|x i -x i-1 The arithmetic mean of all actual center-to-center distances is taken as the average actual center-to-center distance. The outer diameter d of the enameled wire including the enamel film is used as the preset target center-to-center distance, and the preset distance tolerance ε is set to 0.05d; when the average actual center-to-center distance is greater than... When k decreases, the average actual center spacing is less than Increase k by 0.01 to 0.05 each time until the absolute value of the deviation between the average actual center distance and d is no greater than ε; for fine enameled wire with a diameter of 0.03 mm to 0.10 mm, k is preferably calibrated in the range of 0.85 to 1.15.

[0045] The correction amount δ is used to change the positional relationship between the candidate line turn and the adjacent line turn and the boundary of the allowable height area. If δ is too small, the occupied units corresponding to the three candidate line landing positions are basically the same, and an effective correction cannot be formed. If δ is too large, it may disrupt the tight arrangement of the adjacent line turns. In this embodiment, δ is preferably 0.2 times d.

[0046] After determining the three candidate landing positions, the control device also performs a boundary check on the candidate positions; specifically, it extends d to each side of the candidate landing position as the center. e The effective occupancy area formed by half of the wire should be completely located within the available wiring area; if the effective occupancy area extends beyond the effective support area of ​​the stator tooth end face to be wound or the wiring area defined by the insulation structure, the corresponding candidate wire placement position will not be included in the subsequent deduction.

[0047] The three candidate drop positions are centered on the normal adjacent wire pitch, with only limited corrections to the near and far sides, maintaining the basic arrangement relationship of adjacent wire turns, providing different actual space occupation schemes for the subsequent judgment of the feasibility of remaining wire turns, and changing the local space allocation method without changing the basic winding trajectory of the guide needle.

[0048] Step S3: For the baseline drop line position, the first modified drop line position, and the second modified drop line position, assume that the next winding is formed at the corresponding candidate drop line position, and obtain the corresponding assumed winding occupancy state; that is, copy the current winding occupancy state obtained in step S1 inside the control device, virtually place the next winding on the three candidate positions, calculate the end face occupancy and winding height after each placement method, and obtain three independent calculation branches.

[0049] Specifically, assuming the winding occupancy state is a temporary state used for predictive calculation, its data structure is the same as the current winding occupancy state. However, assuming the next turn in the winding occupancy state has not yet been actually formed, for a certain candidate drop position p, the control device copies h of each currently occupancy unit. j Given the current layer, current cabling direction, number of completed turns, and most recent drop position, the candidate drop position p is used as the virtual drop position for the (n+1)th turn. Based on p and d... e Determine the occupancy unit of the coverage according to the support height h. s With effective floor height h eThe sum of these values ​​updates the temporary height, forming the assumed winding occupancy state corresponding to the candidate drop position.

[0050] When updating the assumed winding occupancy status, an instantaneous height check is performed on the current candidate position. For occupancy cells covered by candidate turns, the calculated top height h is compared. new The allowable winding end height H corresponding to this occupied unit j Only when all covered and occupied units satisfy h new H j Only when the candidate wire landing position is selected will it be retained and included in the remaining wire turn deduction. When a candidate wire turn crosses two cabling areas with different allowable heights, all occupied units actually covered by it are compared separately to avoid height judgment errors when the center of the wire turn is located in the higher allowable area while the edge of the wire turn enters the lower allowable area.

[0051] Allowable winding end height H j This represents the net axial distance from the uniform height reference plane to the highest permissible position of the winding top at the corresponding end face location, and the permissible winding end height H corresponding to the j-th occupied unit. j Determined based on the actual available axial space of the target motor at that location, satisfying... ; where D j D represents the minimum nominal distance from the uniform height reference plane to the axially adjacent structure at the location of the j-th occupied unit; when this location corresponds to multiple axially adjacent structures, D... j Take the minimum value among the corresponding axial distances of adjacent structures; T i,j q represents the influence of the i-th assembly dimension, tolerance, or component position error on the available axial space at that position in the unfavorable direction; q represents the number of error terms involved in the axial tolerance calculation; S j To allow for a safety clearance; the safety clearance is used to prevent the top of the calculation winding from theoretically just contacting the adjacent components, and is determined according to the product's axial tolerance chain, preferably 0.05 mm to 0.15 mm in micro motors.

[0052] Step S4: Starting from the assumed occupancy state of each reserved winding, the remaining turns are deduced sequentially according to the actual winding order to obtain the subsequent winding position sequence corresponding to the candidate falling position.

[0053] Specifically, let N be the total number of turns to be wound on the stator teeth, n be the number of turns that have been actually completed, and the turn to be formed is the (n+1)th turn. For a certain assumed winding occupancy state established in step S3, the (n+1)th turn has been added as a virtual turn. Subsequent deductions start from the (n+2)th turn and proceed in ascending order of turn number until the Nth turn. If n+1=N, the current candidate position is considered to have completed the remaining turn winding after the instant height check, and no additional virtual turns are generated.

[0054] When a virtual wire turn is generated, the most recent wire drop position, current wiring direction, current layer and height of each occupied unit in the current virtual state are read. The reference wire drop position, first corrected wire drop position and second corrected wire drop position of the virtual wire turn are generated according to the same calculation rules as in step S2. Boundary checks and allowable height checks are performed in the order of reference wire drop position, first corrected wire drop position and second corrected wire drop position.

[0055] After determining the virtual drop position of a virtual coil, the virtual coil is added to the virtual winding occupancy state according to the same height update rule as in step S3, and the adopted virtual drop position is written into the subsequent wiring position sequence in sequence, and then the next virtual coil is generated. When the three candidate drop positions of a virtual coil do not meet the boundary conditions or allowable height conditions in the current winding layer, a layer change judgment is performed. When changing layers, the winding layer is increased by one layer, and the last determined virtual drop position of the current winding layer before the layer change is taken as the nearest drop position after the layer change. The wiring direction is reversed, and the reference drop position, the first corrected drop position and the second corrected drop position of the next winding layer are regenerated according to the nearest drop position after the layer change, the reversed wiring direction and the same calculation rule as in step S2.

[0056] The layer switching trigger condition is that the current virtual turn cannot continue to form at any of the three candidate landing positions in the current layer, and the specified total number of turns has not yet been reached; the wiring direction after the layer switch is opposite to that of the current layer, so that adjacent winding layers form a round-trip wiring; if the product design limits the maximum number of winding layers L max Then the number of virtual layers must not exceed L. max L max Based on the pre-determined allowable winding end height and effective layer height at each location within the available wiring area, when the number of virtual layers reaches L... max If there are still no available candidate landing positions, the corresponding deduction branch is determined to be unable to complete the specified total number of turns.

[0057] To avoid local height distortion caused by estimating only the number of layers, the actual calculated top height of each occupied unit is retained after each virtual layer change; for example, if some positions in the lower layer have already formed a high top due to overlapping wires, the new layer of wires will cover that position with a higher h. j As the support height, the obtained hnew This increase causes the subsequent wiring sequence to be simultaneously limited by the remaining lateral space and the remaining axial height.

[0058] The termination conditions for step S4 include two cases: the first case is that the virtual turn number reaches N, and each virtual turn starting from the current candidate fall position obtains a fall position that meets the conditions. At this time, the corresponding subsequent wiring position sequence is marked as complete. The second case is that there is no candidate fall position that meets the boundary and allowable height for a certain virtual turn in the current layer and in the allowed subsequent winding layers. At this time, the branch deduction is stopped, and the initial current candidate fall position is marked as incomplete.

[0059] Step S5: Based on the subsequent wiring position sequence corresponding to each candidate falling position, determine whether the remaining wire turns can be wound within the allowable winding end height of the corresponding position, eliminate candidate falling positions that cannot be wound, and determine the target falling position from the candidate falling positions that have been wound.

[0060] Specifically, for any candidate drop position to be considered as completed winding, three conditions must be met simultaneously: each turn from the current turn to the Nth turn must have a drop position; the effective occupancy range of each drop position must be within the available wiring area of ​​the corresponding winding layer; and the calculated top height after each update must not be greater than the allowable winding end height of the corresponding occupancy unit.

[0061] When the required total number of turns has been completed at multiple candidate landing positions, the target landing position is determined according to the priority order of the baseline landing position, the first corrected landing position, and the second corrected landing position. The baseline landing position corresponds to the normal cabling pitch, and the baseline landing position is used first to maintain the arrangement pattern of adjacent turns. The corrected position is only used if the baseline landing position would prevent the completion of subsequent turns. To reduce the amount of calculation, in actual control, only the baseline landing position is fully simulated first. If the baseline landing position can be completed, it is directly determined as the target landing position. If the baseline landing position cannot be completed, the first corrected landing position and the second corrected landing position are simulated in sequence.

[0062] When none of the three candidate winding positions can yield a complete subsequent winding sequence in the current layer, the next turn is not forcibly formed in the current layer. Instead, the current winding layer is terminated, a new winding layer is added, and the winding is reversed. Then, steps S2 to S5 are re-executed in the state after the layer change. If the maximum number of winding layers specified by the product is reached and a subsequent winding sequence covering the specified total number of turns still cannot be generated, the control device stops the continued winding of the current stator tooth to be wound and outputs a state that the winding cannot be completed. The state records at least the current turn number, the winding area where the limit is exceeded, and the corresponding calculated top height to confirm whether the specified total number of turns matches the actual available end face space.

[0063] Step S6: Move the wire guide to the wire guide position corresponding to the target wire drop position, and restrict the enameled wire to form at the target wire drop position when the guide needle is releasing the wire from the end face; convert the calculated position obtained in step S5 into the mechanical position executed by the wire guide mechanism, and when the enameled wire passes the end face of the stator tooth to be wound, use the wire guide to restrict the enameled wire from crossing the target boundary, so that the calculated target wire drop position is realized as the actual wire turn position.

[0064] Specifically, a correspondence is established between the target drop position and the mechanical position of the cable assembly through equipment calibration. During debugging, the cable assembly is made to sequentially reach multiple known drive positions X. p Under the condition of maintaining the wire release posture of the guide needle end face and the stability of the winding tension, test wire turns are formed, and the actual wire drop center position x of each test wire turn is measured. Multiple sets of X p Establish a position correspondence table with x; when the cable drive direction is approximately linear with the end face cable direction, the mechanical position X of the cable drive mechanism is... p The relationship between the actual drop position x of the enameled wire and the position x is satisfied Where x is the actual position of the enameled wire on the end face of the stator tooth to be wound, in mm; X p denoted by x, represents the mechanical position of the wire-laying drive mechanism, in mm; 'a' is the proportionality coefficient between the mechanical displacement of the wire-laying drive mechanism and the end-face wire-dropping displacement; 'c' is the zero-point offset between the mechanical position coordinate system and the end-face wire-dropping position coordinate system, in mm; during actual winding, the offset is determined based on the current target wire-dropping position x. t The target mechanical position X of the cable drive mechanism p,t according to The target mechanical position of the wire laying drive mechanism is calculated in reverse. When the mechanism has repeatable nonlinear position errors, multiple calibration points are set within the wire laying drive stroke, and the piecewise linear interpolation relationship between adjacent calibration points is used to determine the target mechanical position, so that the target wire landing position is converted into a mechanical position signal that the wire laying drive mechanism can directly execute.

[0065] After the wire guide reaches the target mechanical position, it remains stable during the wire release stage when the guide needle enters the corresponding axial end face. The enameled wire extends from the guide needle outlet to the end face of the stator tooth to be wound and is restricted by the wire guide part of the wire guide. The wire guide part is located on the side away from the allowed entry area of ​​the target wire drop position, so that the enameled wire adheres to the end face of the stator tooth to be wound under the action of winding tension and forms near the target wire drop position.

[0066] After the current coil is actually formed and stabilized, the winding status detection component obtains the actual landing position of the coil and the top height of the formed winding, and writes the detection result into the current winding occupancy status, increases the number of completed turns by one, and then re-executes steps S1 to S6 for the next coil. The prediction sequence is only used to determine whether the current candidate landing position will affect the completion of the remaining coil winding. Each time a turn is actually formed, it is recalculated based on the latest detection status to reduce the accumulation of errors caused by enameled wire springback, positioning error of the wiring component, or deviation between the actual support status and the predicted value.

[0067] When both the first and second axial end faces of the stator to be wound require winding end height control, the winding status detection component includes a first detection unit and a second detection unit corresponding to the first and second axial end faces, respectively. The two axial end faces establish their respective available wiring areas, occupied units, and current winding top height h based on the detection results of their corresponding detection units. j and allowable winding end height H j And execute steps S1 to S6 respectively; the same number of completed turns and the specified total number of turns are used on the two axial end faces of the same wire turn. The target wire drop position on the first axial end face is determined by the current winding occupancy status and the allowable winding end height of the first axial end face. The target wire drop position on the second axial end face is determined by the current winding occupancy status and the allowable winding end height of the second axial end face. The target wire drop positions, layer replacement timing and wire laying direction of the two axial end faces are different from each other.

[0068] As a direct implementation example of parameters, the available wire width to be wound around the stator tooth end face is 0.60 mm, the outer diameter d of the enameled wire including the enamel film is 0.06 mm, the width of the occupied unit b is 0.02 mm, and 30 occupied units are formed along the wire direction; 0 mm to 0.18 mm is set as the first wire region, 0.18 mm to 0.42 mm is set as the second wire region, and 0.42 mm to 0.60 mm is set as the third wire region. The allowable winding end heights for the three regions are 0.14 mm, 0.20 mm, and 0.14 mm, respectively.

[0069] In the parameter example above, the wiring correction coefficient k is 1, the reference wiring movement Δx is 0.06 mm, and the correction δ is 0.012 mm; when the current coil's center position x c When the value is 0.408 mm and the current cable routing direction is along the x-increasing direction, the reference cable placement position x b The value is 0.468 mm, and the first correction line position is x. a The second correction line position is 0.456 mm. zThe value is 0.480mm; the control device virtually adds the next winding to three positions, updates the corresponding occupied unit height according to its effective occupied range, and continues to deduce the remaining windings from the three assumed winding occupancy states.

[0070] For example, when the current top height of the winding of some occupied units in the third wiring area has reached 0.12 mm, an effective layer height h is then formed at the location covering these occupied units. e For a 0.06 mm wire turn, the calculated top height is 0.18 mm, which is higher than the allowable winding end height of 0.14 mm for this area, so the corresponding candidate position is excluded. When the current winding top height of some occupied units in the second wiring area is also 0.12 mm, adding 0.06 mm to get 0.18 mm still results in a position that is lower than the allowable winding end height of 0.20 mm for this area, and is still considered as a usable position for subsequent virtual wire turns.

[0071] If 0.468 mm is used as the reference landing position for the current next turn, the turn itself meets the allowable height of 0.14 mm. However, after further analysis, it is found that the available position of a subsequent turn in the third wiring area and after the layer change exceeds the corresponding allowable height. Therefore, 0.468 mm is determined to be insufficient to complete the specified total number of turns. The control device continues to establish the first correction assumption state with 0.456 mm. If 0.456 mm enables some subsequent turns to utilize the allowable height of 0.20 mm in the second wiring area, and ultimately enables all virtual turns up to the Nth turn to obtain a position that meets the conditions, then 0.456 mm is determined as the current actual target landing position.

[0072] After completing the prescribed winding of the corresponding winding, the end of the enameled wire is led to the corresponding terminal pin, and then wound or hooked and fixed at the binding part of the terminal pin; subsequently, the enameled wire at the binding part and the terminal pin are tinned to form a stable electrical connection. For example... Figure 5 As shown, after the tinning is completed, a bending mechanism or bending fixture is used to bend the bendable lead-out part of the wire connector, so that the bendable lead-out part is changed from the winding processing position to the final lead-out position required for product assembly.

[0073] Example 3: As Figure 2 and Figure 3As shown, a winding device for performing the aforementioned guide pin winding method includes a frame 1 and a stator clamp 2, a stator drive mechanism 4, a guide pin assembly 5, a guide pin drive mechanism 6, a wire assembly 7, a wire assembly drive mechanism 8, and a control device 9 mounted on the frame 1. The stator clamp 2 is used to position the stator 3 to be wound and is connected to the stator drive mechanism 4. After the stator to be wound is clamped, its central axis corresponds to the rotation axis of the stator drive mechanism. The stator 3 to be wound has multiple stator teeth distributed circumferentially, and a tooth gap is formed between adjacent stator teeth for the guide pin and enameled wire to pass through. The stator drive mechanism 4 drives the stator to be wound to rotate around its own central axis, so that the current stator tooth to be wound can enter the winding position of the guide pin assembly, and completes the tooth changing indexing after the current stator tooth to be wound completes the specified total number of turns.

[0074] The stator 3 to be wound includes a stator core 31, an insulating frame 32 disposed on the stator core, and multiple wiring pins 33 that are injection molded together with the insulating frame as inserts. The exposed portion of the wiring pins 33 forms a wire binding part with an opening and a bendable lead-out part connected to the wire binding part. Before winding the corresponding winding, the starting end of the enameled wire is fixed at the opening of the wire binding part, and the enameled wire is guided by a guide pin to wind the corresponding stator tooth. After completing the specified number of turns of the corresponding winding, the ending end of the enameled wire is fixed to the corresponding wiring pin 33, the connection position between the enameled wire and the wiring pin 33 is tinned, and the bendable lead-out part is bent after the tinning is completed.

[0075] Specifically, the stator fixture uses the center hole of the stator to be wound for positioning and is equipped with a clamping structure that restricts the axial movement and circumferential relative sliding of the stator to be wound. The clamping structure adopts a positioning groove that matches the shape of the stator to be wound. It is sufficient to keep the stator to be wound repeatedly positioned under the action of the guide pin reciprocating through the groove, the rotation of the stator to be wound, and the tension of the enameled wire. The stator drive mechanism adopts a servo motor. The control device outputs an angle command according to the tooth gap position of the stator tooth to be wound, so that the stator to be wound rotates to the position corresponding to the return path of the guide pin during the single turn winding process. After a single stator tooth is fully wound, the indexing is performed according to the number of stator teeth.

[0076] Furthermore, the guide needle assembly 5 includes a guide needle 51 through which the enameled wire passes. A wire passage 52 is formed inside the guide needle, extending to the working end of the guide needle and forming an outlet at the working end. The enameled wire is led out by the wire supply assembly, passes through the tension control assembly, enters the wire passage, and is led out from the outlet to the end face of the stator tooth to be wound. The guide needle drive mechanism 6 is connected to the guide needle assembly and drives the guide needle to reciprocate along the axial direction of the stator to be wound, so that the guide needle can pass through the tooth gap on one side of the stator tooth to be wound, and after the stator to be wound rotates relative to it, pass through the tooth gap on the other side along the opposite axial direction, so that the enameled wire forms a turn around the stator tooth to be wound.

[0077] For ultra-thin micro brushless motor stators with narrow tooth gaps, the working end of the guide pin adopts a flat structure. The thickness dimension of the working end is smaller than the minimum width of the tooth gap, and the width dimension of the working end is determined according to the wire passage and structural strength. In addition to the axial linear drive degree of freedom, the guide pin drive mechanism also has a rotation drive degree of freedom that allows the guide pin to rotate around its own axis. Before entering the tooth gap, the guide pin is in a slotting posture. In the slotting posture, the thickness direction of the working end matches the width direction of the tooth gap. After the guide pin passes through the tooth gap and reaches the end face wire feeding area, the rotation drive degree of freedom drives the guide pin to rotate to the end face wire feeding posture, so that the wire outlet faces the target wire dropping position currently determined by the control device.

[0078] Furthermore, the wiring assembly 7 includes an upper wiring assembly 71 and a lower wiring assembly 72; the upper wiring assembly 71 corresponds to the first axial end face of the stator 3 to be wound, and the lower wiring assembly 72 corresponds to the second axial end face of the stator 3 to be wound. The upper wiring assembly 71 includes a first wiring member for defining the position of the enameled wire falling on the first axial end face side, and the lower wiring assembly 72 includes a second wiring member for defining the position of the enameled wire falling on the second axial end face side. The first wiring member and the second wiring member are respectively connected to the corresponding wiring drive mechanism 8.

[0079] The wire laying component is located near the end face of the stator tooth to be wound, and the wire laying drive mechanism drives the wire laying component to move along the wire laying direction. The wire laying direction is determined according to the available wire laying area of ​​the end face of the stator tooth to be wound. Under regular tooth profile, the wire laying direction is set along the width direction of the stator tooth end face, and under irregular tooth profile, the wire laying direction is set along the main extension direction of the available wire laying area. When the wire laying component is in the first wire laying position, the wire laying part 73 defines the first wire falling area. When the wire laying drive mechanism moves the wire laying component to the second wire laying position, the wire laying part changes its position and defines the second wire falling area, converting the mechanical displacement of the wire laying component into a change in the wire falling position.

[0080] Furthermore, the cable routing drive mechanism 8 adopts a position drive structure capable of outputting controllable linear displacement, including a servo motor and a lead screw transmission pair; the cable routing component is fixed on the slide, the slide is slidably connected to the linear guide, the linear guide limits the movement direction of the cable routing component, and the position drive structure drives the slide to move to the target mechanical position according to the position command output by the control device.

[0081] When the wire guide needs to avoid the movement path of the guide pin, the wire guide has a working position close to the end face of the stator tooth to be wound and a clearance position to avoid the movement path of the guide pin. The wire guide drive mechanism is provided with a first degree of freedom of movement along the wire guide direction and a second degree of freedom of movement along the direction close to or far from the stator to be wound. The second degree of freedom of movement is driven by a cylinder, which causes the wire guide to retract to the clearance position before the guide pin passes through the slot axially, and enter the working position when the working end of the guide pin passes through the tooth gap and enters the end face wire feeding stage. When the equipment space allows the wire guide to never block the movement of the guide pin, the wire guide remains in the working position, and only the first degree of freedom of movement performs the wire guide position change.

[0082] like Figure 3 As shown, a guide pin relief portion 74 is formed on the cable guide component, corresponding to the axial movement path of the guide pin. The guide pin relief portion adopts an open slot, a through notch, a hole, or a partial recess. The size of the guide pin relief portion is based on the fact that the guide pin 51 can pass through in the slotted posture without colliding with the cable guide component. The cable guide portion 73 is set on the side of the guide pin relief portion facing the current cable guide direction. After the guide pin passes through the corresponding position of the guide pin relief portion, the enameled wire is led out from the outlet and is restricted by the cable guide portion after passing through a short free line segment. The relative position of the guide pin relief portion and the cable guide portion allows the cable guide component to be close to the outlet position of the guide pin, while not occupying the movement space required for the guide pin to pass through the tooth gap.

[0083] Furthermore, the wire routing assembly includes a first wire routing component disposed on the first axial end face of the stator to be wound and a second wire routing component disposed on the second axial end face of the stator to be wound. The first and second wire routing components are respectively connected to corresponding wire routing drive mechanisms. The first wire routing component is used to limit the first target wire drop position when the enameled wire passes through the first axial end face, and the second wire routing component is used to limit the second target wire drop position when the enameled wire passes through the second axial end face. Both wire routing drive mechanisms are connected to a control device. The control device respectively stores the wire routing area, allowable winding end height, winding occupancy status, candidate wire drop position, and target wire drop position of the first and second axial end faces, so that the same turn of enameled wire can form end routing according to each other's independent spatial constraints on the two axial end faces.

[0084] When there are different assembly spaces on both sides of the stator, before the same turn is formed, the control device determines the corresponding winding occupancy state based on the actual falling position of the two end faces and the top height of the winding obtained by the first detection unit and the second detection unit, and performs candidate falling position deduction respectively, so that the first wire assembly and the second wire assembly execute different target mechanical positions, thereby making the winding end shape of the two axial end faces adapt to the available axial space on the corresponding side.

[0085] The winding status detection component is fixed to the frame and positioned facing the axial end face of the stator teeth to be wound. Both the position detection unit and the height detection unit are connected to the control device. The field of view of the position detection unit covers the available wiring area, while the detection range of the height detection unit covers all occupied units positioned along the wiring direction. When height control is performed on both axial end faces, corresponding position detection units and height detection units are respectively installed on the first and second axial end faces, allowing the actual wire placement position and the top height of the winding on both end faces to be detected and updated separately.

[0086] Furthermore, the control device includes a processor, a memory, a motion control module, an input / output module, and a human-machine interface module. The memory stores product winding parameters, mechanism calibration parameters, and operating status data. Product winding parameters include the specified total number of turns, enameled wire outer diameter, effective occupied width, effective layer height, reference wire laying movement, correction amount, preset initial wire placement position, preset initial wire laying direction, wire laying area boundary, allowable winding end height, and available wire laying range for each axial end face. Mechanism calibration parameters include the axial stroke of the guide pin, guide pin attitude angle, stator single-turn rotation angle, tooth changing indexing angle, the correspondence between the mechanical position of the wire laying drive mechanism and the wire placement position, and the correspondence between the detection coordinates of the winding status detection component and the end face position coordinates. Operating status data includes the number of completed turns, current winding occupancy status, current layer direction, current turn to be formed, and the assumed winding occupancy status corresponding to each candidate wire placement position.

[0087] When the control device executes the winding method, it forms the first turn of wire according to the preset initial drop position and preset initial wire laying direction when the stator teeth to be wound begin to be wound. It also establishes the current winding occupancy status after the formation of the first turn based on the detection results of the winding status detection component. Starting from the second turn, the control device determines the reference drop position, the first corrected drop position, and the second corrected drop position based on the current winding occupancy status before each turn is formed. It establishes the hypothetical winding occupancy status corresponding to the three candidate drop positions respectively. Starting from each hypothetical winding occupancy status, it determines the laying position of the subsequent turns in sequence according to the winding order of the remaining turns. It judges whether the remaining turns can be wound based on the allowable winding end height of the corresponding position, eliminates the candidate drop positions that cannot complete the specified winding, and then determines the target drop position from the candidate drop positions that can complete the specified winding. After the target drop position is determined, the control device converts the target drop position into the target mechanical position of the wire laying drive mechanism and coordinates the stator drive mechanism, the guide pin drive mechanism, and the wire laying drive mechanism to complete the end face wire laying.

[0088] In the conversion between the target drop position and the mechanical position of the wire laying drive mechanism, the drop position calibration is performed after the equipment assembly is completed; when the mechanical displacement of the wire laying drive mechanism is approximately linearly related to the end face drop position, the following is adopted: Establish a correspondence, where x is the actual position of the enameled wire falling on the end face of the stator tooth to be wound, X p Here, 'a' represents the mechanical position of the wire-laying drive mechanism, 'a' is the proportional coefficient, and 'c' is the zero-point offset. During actual wire winding, the control device calculates the target mechanical position based on the current target wire-laying position. When the mechanism has repeatable nonlinear position errors, multiple calibration points are set within the wire-laying drive stroke, and piecewise linear interpolation between adjacent calibration points is used to determine the target mechanical position, so that the target wire-laying position calculated by the method can be converted into a position command that the wire-laying drive mechanism can execute.

[0089] Furthermore, the control device also stores the correspondence between the allowable winding end height and the equipment coordinates. Each occupied unit or each wiring area corresponds to an allowable winding end height. This allowable winding end height is determined based on the minimum nominal distance from the rotor, drive circuit board, housing, or other axially adjacent structures of the target motor to a unified height reference plane, and after deducting assembly tolerances, component position errors, and reserved safety clearances. When the control device is deducing candidate winding positions, it compares the end height of each assumed coil after formation with the allowable winding end height at the corresponding position. Only candidate wiring results that do not exceed the allowable winding end height are considered as results that can complete the winding of the remaining coils.

[0090] In the actual formation process of a single-turn wire, the control device first calculates the target wire drop position of the current end face according to the method, and makes the corresponding wire laying component reach the target mechanical position. When the guide needle is in the slotting posture, the guide needle drive mechanism drives the guide needle to pass through the tooth gap on one side of the stator tooth to be wound along the axis. After the working end of the guide needle passes through the tooth gap, the guide needle rotates to the end face wire laying posture, and the enameled wire extends from the wire outlet to the current end face. The wire laying part is on the side away from the enameled wire's allowed entry area at the target wire drop position, restricting the enameled wire from crossing the target wire drop position. After the end face wire is maintained under the winding tension and the stator tooth end face support, the control device allows the guide needle posture and the wire laying component position to enter the next action state.

[0091] The stator drive mechanism drives the stator to be wound to rotate relative to each other, causing the enameled wire to cross the current stator tooth and align the tooth gap on the other side with the return path of the guide pin. Before the guide pin passes through the tooth gap on the other side along the opposite axis, the control device confirms that the wire laying component corresponding to the other end face has reached the target mechanical position according to the target wire drop position of that end face. After the guide pin passes through the tooth gap on the other side and enters the end face wire laying posture, the wire laying part of the other wire laying component defines the wire drop position of the enameled wire on the other end face. After the end face wiring of both axial end faces is formed, the control device increases the number of completed turns by one turn and updates the actual winding occupancy status of the first and second axial end faces according to the actual target wire drop position.

[0092] To ensure that the movement of the guide pin, the wire guide assembly, and the stator to be wound does not interfere with each other, before the guide pin enters the tooth gap axially, the control device confirms that the corresponding wire guide assembly is in a clearance position, or confirms that the guide pin clearance part of the wire guide assembly corresponds to the movement path of the guide pin; before the wire guide assembly moves along the wire guide direction, the control device confirms that the guide pin is not in a position that would intersect with the movement path of the wire guide assembly; before the stator drive mechanism performs a single-turn rotation, the control device confirms that the enameled wire is restricted by the wire guide assembly and is in the tension state allowed during the end face unwinding stage; if any position feedback does not reach the predetermined range, the control device suspends subsequent actions and outputs an alarm signal.

[0093] Furthermore, the wire supply assembly and tension control assembly are located on the wire inlet side of the guide needle assembly. The wire supply assembly is used to continuously supply enameled wire to the guide needle, and the tension control assembly is used to stabilize the tension of the enameled wire during the reciprocating motion of the guide needle, the switching of the guide needle's posture, and the rotation around the stator. The tension control assembly includes a tensioner, a wire storage structure to compensate for the instantaneous changes in wire quantity caused by the commutation of the guide needle and the rotation of the stator, and a tension detection element to feed the tension signal back to the control device. The control device adjusts the wire supply damping, pauses the action, or reduces the movement speed according to the tension status to prevent the enameled wire from deviating from the restricted area of ​​the wire laying section due to excessively low tension.

[0094] The wiring component maintains a gap between its working position and the end face of the stator tooth to be wound, allowing the enameled wire to pass through and form the end face wiring, while preventing the wiring component from pressing on the already formed wire turn. The working position of the wiring component is determined by equipment calibration. During calibration, the wiring component is brought close to the end face of the stator tooth to be wound, and the working position parameters of the corresponding product are obtained based on the judgment condition that the wiring part can restrict the newly formed enameled wire without pressing on the existing wire turn.

[0095] When the control device determines, based on the method, that neither the reference drop position, the first corrected drop position, nor the second corrected drop position within the current winding layer can enable the remaining turns to complete winding at the allowable winding end height, the control device ends the current winding layer's wiring and sets the next turn to enter the adjacent winding layer. The wiring component moves in the opposite direction to the current wiring direction. The wiring drive mechanism does not need to change its structure; it only needs to move in the opposite direction according to the target mechanical position updated by the control device. The guide pin and stator drive mechanism still perform single-turn forming actions.

[0096] In a specific equipment parameter, the effective wire width of the stator tooth end face to be wound is 0.60 mm, the outer diameter of the enameled wire is 0.06 mm, and the occupied width is 0.02 mm. When this is the case, the control device divides the wire winding area of ​​a single end face into 30 occupied units. The wire winding drive mechanism uses a servo motor in conjunction with a lead screw transmission pair. The lead screw lead is 1 mm, and the encoder resolution meets the position control requirements of the wire winding component within 0.01 mm. The wire winding correction coefficient is determined through trial winding. The actual falling center position of adjacent turns is obtained using the position detection unit, and the wire winding correction coefficient is adjusted according to the deviation between the actual center distance of adjacent turns and the preset target center distance. When the absolute value of the deviation is not greater than the preset distance tolerance, the control device saves the corresponding reference wire winding movement. The candidate falling position of each subsequent turn is generated based on the reference wire winding movement and is deduced and judged in combination with the correction amount.

[0097] Accordingly, if the three wiring areas of the first axial end face correspond to allowable winding end heights of 0.12 mm, 0.18 mm, and 0.12 mm respectively, and the second axial end face corresponds to allowable winding end heights of 0.10 mm, 0.16 mm, and 0.14 mm respectively, then the control device performs candidate position deduction on the two end faces before the same turn is formed; the first wiring component moves according to the target wire drop position deduced from the first axial end face, and the second wiring component moves according to the target wire drop position deduced from the second axial end face. When the guide pin releases wire on the two end faces, it cooperates with the corresponding wiring component respectively, so that the two ends of the same turn can be formed at different wire drop positions; the above values ​​are only used to illustrate the cooperation between the control device, the wiring drive mechanism, and the guide pin action. In actual products, the effective wiring width, allowable winding end height, enameled wire outer diameter, and occupied unit width are all determined according to the structural dimensions and winding design of the target motor.

[0098] Based on the preferred embodiments of the present invention described above, and through the above description, those skilled in the art can make various changes and modifications without departing from the technical concept of the present invention. The technical scope of the present invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A guide pin winding method for the stator of an ultra-thin micro brushless motor, characterized in that, Includes the following steps: S1, guide the enameled wire through the gap between the teeth on both sides of the stator tooth to be wound to form a wire turn, take the most recently formed wire turn as the current wire turn, and determine the current winding occupancy status according to the falling position of the already formed wire turn and the top height of the winding before forming the next wire turn. S2, determine the reference drop position of the next winding based on the current winding occupancy status, and determine the first corrected drop position and the second corrected drop position on the two sides of the reference drop position facing and away from the current winding, respectively. S3, respectively assume that the next winding is formed at the reference drop position, the first corrected drop position and the second corrected drop position, and obtain the corresponding assumed winding occupancy state according to the winding occupancy range and the top height of the winding corresponding to each drop position. S4. Starting from the assumed winding occupancy status, determine the wiring position of the subsequent windings in sequence according to the winding order of the remaining windings, and determine whether the remaining windings can be wound according to the allowable winding end height at the corresponding position, thus forming the corresponding subsequent wiring position sequence. S5, eliminate the drop positions that cannot complete the remaining wire turns, and determine the target drop position from the drop positions that can complete the remaining wire turns. S6, control the cable tray to move to the cable tray position corresponding to the target drop position, and when the guide needle is releasing the wire from the end face, the cable tray limits the formation of the enameled wire at the target drop position.

2. The guide pin winding method for the stator of an ultra-thin micro brushless motor according to claim 1, characterized in that: The available wiring area on the end face of the stator tooth to be wound is divided into a first wiring area, a second wiring area and a third wiring area along the wiring direction. The first wiring area, the second wiring area and the third wiring area correspond to the first allowable winding end height, the second allowable winding end height and the third allowable winding end height, respectively. The second allowable winding end height is greater than the first allowable winding end height and the third allowable winding end height. When determining the subsequent wiring sequence, the wiring position of the turn is judged to see if it meets the winding conditions based on the allowable winding end height corresponding to the wiring area where the turn is located.

3. The guide pin winding method for the stator of an ultra-thin micro brushless motor according to claim 2, characterized in that: The reference drop position is determined based on the current drop position of the line turn and the amount of reference line movement. The first corrected placement position is located on the side of the reference placement position facing the placement position of the current coil, and the second corrected placement position is located on the side of the reference placement position away from the placement position of the current coil; the subsequent wiring position sequence is determined according to the order of the reference placement position, the first corrected placement position, and the second corrected placement position.

4. The guide pin winding method for the stator of an ultra-thin micro brushless motor according to claim 3, characterized in that: The reference cable movement is determined based on the outer diameter of the enameled wire and the cable correction factor. The wiring correction coefficient is determined by trial winding of stators and enameled wires of the same specifications; during the trial winding process, the actual center position of adjacent turns is obtained, and the wiring correction coefficient is adjusted according to the deviation between the actual center distance of adjacent turns and the preset target center distance until the absolute value of the deviation is not greater than the preset distance tolerance.

5. The guide pin winding method for the stator of an ultra-thin micro brushless motor according to claim 1, characterized in that: The current winding occupancy status also includes the current winding layer and the current wiring direction; first assume that the next turn is formed at the reference drop position, and determine the wiring position of the subsequent turns in sequence according to the winding order of the remaining turns; When the subsequent wiring position sequence formed by the reference falling position cannot complete the remaining wire turns, the subsequent wiring position sequence is determined sequentially for the first corrected falling position and the second corrected falling position. When the subsequent wiring sequence corresponding to the reference falling position, the first corrected falling position, and the second corrected falling position cannot complete the remaining wire turns, the wiring of the current winding layer ends, the next wire turn enters the next winding layer, and the wiring component moves in the opposite direction to the current wiring direction.

6. A guide pin type winding device for the stator of an ultra-thin miniature brushless motor, characterized in that: It includes a stator clamp, a stator drive mechanism, a guide pin assembly, a guide pin drive mechanism, a cable assembly, a cable drive mechanism, a winding status detection assembly, and a control device; The stator clamp is connected to the stator drive mechanism and is used to position the stator to be wound and drive the stator to be wound to rotate. The guide pin assembly includes a guide pin through which the enameled wire passes, and the guide pin driving mechanism drives the guide pin to pass through the tooth gap on both sides of the stator tooth to be wound along the axial direction of the stator to be wound. The wiring assembly includes a wiring component disposed on the first axial end face side of the stator to be wound, and the wiring drive mechanism drives the wiring component to move along the wiring direction of the stator tooth end face to be wound. The winding status detection component is disposed on the axial end face of the stator to be wound and connected to the control device, including a position detection unit for obtaining the actual falling position of the formed coil and a height detection unit for obtaining the top height of the winding at the corresponding position. The control device is connected to the stator drive mechanism, the guide pin drive mechanism and the wire laying drive mechanism respectively. The control device determines the current winding occupancy status based on the falling position of the formed coil and the top height of the winding, determines the reference falling position, the first corrected falling position and the second corrected falling position of the next coil, and determines the target falling position so that the remaining coil can be wound according to the allowable winding end height by establishing the assumed winding occupancy status corresponding to the three falling positions respectively, and controls the wire laying component to move to the wire laying position corresponding to the target falling position.

7. A guide pin type winding device for the stator of an ultra-thin micro brushless motor according to claim 6, characterized in that: The wiring component has a working position close to the end face of the stator tooth to be wound and a clearance position avoiding the movement path of the guide pin. The wiring drive mechanism drives the wiring component to move between the working position and the clearance position. The wiring component forms a guide needle avoidance part for the guide needle to pass through and a wiring part for limiting the position of the enameled wire drop. The wiring part is located on the side of the guide needle avoidance part facing the wiring direction, and is located in a restricted position corresponding to the target drop position when the guide needle is releasing the wire from the end face.

8. A surface-mount ultrathin miniature brushless motor stator assembly, characterized in that: It includes a stator core, an insulating frame disposed on the stator core, a winding wound on the stator core, and multiple terminal pins; The outer diameter of the stator core is less than 6.5 mm, and the insulating frame is provided with a pin retaining structure for fixing the wiring pins; The plurality of wiring pins are electrically connected to the starting end and / or ending end of the winding, respectively. The wiring pins include a fixing part connected to the insulating frame and a bendable lead-out part extending from the fixing part. The bendable lead-out part is bent and shaped to form a mounting part. The plurality of mounting parts are located on the same mounting side of the stator assembly and respectively form a soldering surface for connecting to the corresponding pad of the flexible circuit board. At least a portion of the winding is provided with a high-temperature resistant curing material to restrict the displacement of the turns in the winding relative to the stator core and / or the insulating frame, so that the stator assembly can be mounted on a flexible circuit board as a surface mount device.

9. A surface-mount ultra-thin miniature brushless motor stator assembly according to claim 8, characterized in that: The stator assembly also includes a high-temperature resistant encapsulation covering the outside of the insulating frame and / or windings, the high-temperature resistant encapsulation being formed of liquid crystal polymer (LCP) material.

10. A surface-mount ultra-thin miniature brushless motor stator assembly according to claim 8, characterized in that: The high-temperature resistant curing material includes a high-temperature resistant UV curing adhesive, which is disposed at least between adjacent turns and / or between the winding and the insulating frame.

Images