Motor flat wire hairpin forming device

Abstract

The utility model discloses a motor flat wire clamping and forming device which comprises a convex surface mold and a concave surface mold which are oppositely arranged, an air cylinder for driving the concave surface mold to move relative to the convex surface mold, a first lifting mechanism for driving the convex surface mold to do lifting motion, a bending module and a second lifting mechanism for driving the bending module to do lifting motion, each of the convex surface mold and the concave surface mold comprises a bending forming area and a bending forming area; the bending forming area comprises vertical grooves formed in the two ends of the convex face mold and allowing the bending modules to vertically pass through, and bending grooves formed in the two ends of the concave face mold and allowing the two ends of the flat wire to be bent and formed. The bending forming area comprises a first forming face, a second forming face, a third forming face and a fourth forming face which are used for bending the first side face, the second side face, the third side face and the fourth side face of the flat wire respectively. By means of the structural design of the scheme, the copper wire can be formed into the flat wire in the needed shape on the same device at a time.

Description

Technical Field

[0001] The utility model relates to motor manufacturing technology, in particular to a motor flat wire card forming device. Background Art

[0002] Compared with the round wire in the round wire motor, the flat wire of the same cross-sectional area occupies less space when arranged due to its shape characteristics. Therefore, a flat wire with a larger cross-section can be wound into the same winding slot space. At present, the flat wire is mainly made of copper wire stamping, such as Figure 4 As shown in FIG. 1 , the overall shape is U-shaped and the width direction is wavy. The flat wire has four sides and its cross section is rectangular.

[0003] Due to the special structure of the flat wire, the existing flat wire forming device needs to undergo two forming processes, namely, 2D forming in the plane and then 3D forming in space. It often requires two processes and two sets of forming molds, which increases production costs and reduces production efficiency. Utility Model Content

[0004] In view of the above-mentioned deficiencies in the prior art, the utility model provides a motor flat wire hairpin forming device, which solves the problem in the prior art that the flat wire needs to be formed twice through two sets of forming dies.

[0005] In order to achieve the above purpose, the technical solution adopted by the utility model is:

[0006] Provided is a motor flat wire hairpin forming device, which comprises a convex mold and a concave mold arranged opposite to each other, a cylinder driving the concave mold to move relative to the convex mold, a first lifting mechanism driving the convex mold to do lifting movement, a bending module, and a second lifting mechanism driving the bending module to do lifting movement; the convex mold and the concave mold both comprise a press-bending forming area and a bending forming area;

[0007] The bending and forming area includes vertical grooves provided at both ends of the convex mold for the bending module to pass vertically, and bending grooves provided at both ends of the concave mold for the two ends of the flat wire to be bent and formed;

[0008] The bending and forming area includes a first forming surface, a second forming surface, a third forming surface and a fourth forming surface for bending the first side surface, the second side surface, the third side surface and the fourth side surface of the flat wire respectively;

[0009] The first molding surface and the second molding surface are arranged on the convex mold, and the third molding surface and the fourth molding surface are arranged on the concave mold; and the first molding surface is arranged opposite to the third molding surface, and the second molding surface is arranged opposite to the fourth molding surface.

[0010] The beneficial effects of the utility model are as follows: during forming, the copper wire is placed between the convex mold and the concave mold, the cylinder first drives the concave mold to move relative to the convex mold, and the impact force makes the copper wire and the mold closely contact and form. The first forming surface of the convex mold and the third forming surface of the concave mold respectively form the first side surface and the third side surface of the copper wire.

[0011] Then the first lifting mechanism drives the convex mold to press downward, and the second molding surface of the convex mold and the fourth molding surface of the concave mold respectively mold the second side surface and the fourth side surface of the copper wire.

[0012] Finally, the bending module is in close contact with the copper wire, and the second lifting mechanism drives the bending module to move downward along the vertical groove, so that the copper wire is pressed into the U-shape of the bending groove as the bending module moves.

[0013] After the above steps, the flat wire can be formed at one time on the same device, which not only saves the cost of purchasing equipment, but also greatly shortens the transportation time between different processes and improves production efficiency.

[0014] Further, the convex mold includes a lower convex molding block and an upper convex molding block protruding from the lower convex molding block; the concave mold includes an upper concave molding block and a lower concave molding block protruding from the upper concave molding block;

[0015] The step surfaces of the upper convex molding block and the lower concave molding block are respectively the second molding surface and the fourth molding surface which are opposite to each other; the second molding surface and the fourth molding surface are arched surfaces with shapes matching each other.

[0016] The convex mold and the concave mold are both step-shaped molding blocks, and their step surfaces are arranged oppositely. The flat wire is placed on the fourth molding surface, and then the convex mold is driven downward by the first lifting mechanism, and the second side surface and the fourth side surface of the flat wire are in close contact with the second molding surface and the fourth molding surface respectively to press out a U-shaped bottom.

[0017] Furthermore, the sides opposite to each other of the upper convex forming block and the upper concave forming block are both curved surfaces with wavy curves; the sides opposite to each other of the lower convex forming block and the lower concave forming block are respectively consistent with the outer contours of the curved surfaces of the upper convex forming block and the upper concave forming block;

[0018] The first molding surface is the arc surface of the lower convex molding block, and the third molding surface is the arc surface of the upper concave molding block, so as to facilitate molding the first side surface and the third side surface of the flat wire into arc surfaces with wavy curves.

[0019] Furthermore, the bottom surface of the bending groove and the fourth forming surface of the concave forming block form a continuous smooth surface, and the connection between the bottom surface and the fourth forming surface is provided with an arc chamfer. The shape of the formed flat wire is a line extending along the fourth forming surface and the bottom surface.

[0020] Furthermore, both ends of the second forming surface are provided with arc-shaped chamfered portions; both ends of the upper concave forming block close to the bending groove are provided with arc-shaped chamfered portions; and the four corners of the lower concave forming block located in the bending forming area are provided with arc-shaped chamfered portions. The structure is optimized, and multiple edges are chamfered to avoid damage to the copper wire caused by sharp edges during the mold closing process.

[0021] Furthermore, the molding device also includes a bottom plate, on which a first mounting frame and a second mounting frame are arranged; the second mounting frame is slidably connected to the bottom plate through a horizontal guide rail, and the first mounting frame is fixedly connected to the bottom plate;

[0022] The convex mold is slidably connected to the first mounting frame through the first guide rail; the concave mold is fixedly connected to the second mounting frame; and the second mounting frame is connected to the cylinder.

[0023] The cylinder drives the second mounting frame to move along the horizontal guide rail so that the concave mold moves linearly relative to the convex mold. The convex mold can move linearly along the first guide rail due to the drive of the first lifting mechanism.

[0024] Furthermore, the bending module includes a pressing wheel and a mounting block arranged on both sides of the concave mold, the mounting block is slidably connected to the second mounting frame through a second guide rail; the pressing wheel is rotationally connected to the mounting block through a shaft.

[0025] The curved surface of the pressing wheel contacts the copper wire when in use, and the copper wire can be bent along the vertical grooves on both sides of the bending groove by moving downward. In addition, the pressing wheel can rotate, so the friction mode between it and the copper wire is rolling friction rather than sliding friction, which can reduce friction and reduce friction damage to the copper wire.

[0026] Furthermore, the first mounting frame is fixedly connected to a wire-passing assembly block arranged on both sides of the convex mold; the wire-passing assembly block includes a support plate and a cross plate arranged in parallel and connected to each other, and a mounting groove is formed between the support plate and the cross plate. When in use, the two ends of the copper wire are respectively inserted into the two mounting grooves. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 Schematic diagram of a convex mold and a concave mold;

[0028] Figure 2 This is a front view of the motor flat wire hairpin forming device;

[0029] Figure 3 This is an isometric view of the motor flat wire hairpin forming device;

[0030] Figure 4 It is a schematic diagram of the structure after the flat wire is formed;

[0031] Figure 5 It is a structural diagram of the convex mold and the concave mold;

[0032] Figure 6 for Figure 1 A magnified image of point A;

[0033] Figure 7 It is a schematic diagram of the structure of the convex mold.

[0034] Among them, 1. convex mold; 11. lower convex molding block; 111. first molding surface; 12. upper convex molding block; 121. second molding surface; 13. first mounting frame; 14. vertical groove; 131. first guide rail; 2. concave mold; 21. lower concave molding block; 211. fourth molding surface; 212. connecting part; 213. bottom surface; 22. upper concave molding block; 221. third molding surface; 23. second mounting frame; 231. second guide rail; 24. bending groove; 3. bottom plate; 31. horizontal guide rail; 4. wire assembly block; 41. support plate; 42. horizontal plate; 5. bending module; 51. pressure wheel; 52. mounting block; 6. flat wire; 61. first side surface; 62. second side surface; 63. third side surface; 64. fourth side surface; 7. chamfering part. DETAILED DESCRIPTION

[0035] The specific implementation methods of the utility model are described below to facilitate technical personnel in this technical field to understand the utility model, but it should be clear that the utility model is not limited to the scope of the specific implementation methods. For ordinary technical personnel in this technical field, as long as various changes are within the spirit and scope of the utility model defined and determined by the attached claims, these changes are obvious, and all utility model creations using the concept of the utility model are protected.

[0036] like Figures 2-3 As shown, the motor flat wire hairpin forming device of this scheme includes a convex mold 1 and a concave mold 2 arranged relatively, a cylinder driving the concave mold 2 to move relative to the convex mold 1, and a first lifting mechanism driving the convex mold 1 to perform lifting movement.

[0037] The molding device also includes a bottom plate 3, on which a first mounting frame 13 and a second mounting frame 23 are arranged; the second mounting frame 23 is slidably connected to the bottom plate 3 through a horizontal guide rail 31, and the first mounting frame 13 is fixedly connected to the bottom plate 3. The cylinder drives the second mounting frame 23 to move along the horizontal guide rail 31 so that the concave mold 2 moves linearly relative to the convex mold 1.

[0038] The convex mold 1 is slidably connected to the first mounting frame 13 through the first guide rail 131; the concave mold 2 is fixedly connected to the second mounting frame 23; and the second mounting frame 23 is connected to the cylinder. The convex mold 1 can perform linear lifting motion along the first guide rail 131 due to the drive of the first lifting mechanism.

[0039] like Figure 1As shown, the convex mold 1 and the concave mold 2 both include a press-bending molding area and a folding molding area; the molding device also includes a folding module 5 and a second lifting mechanism for driving the folding module 5 to perform lifting motion.

[0040] The bending and forming area includes vertical grooves 14 opened at both ends of the convex mold 1 for the bending module 5 to pass vertically, and bending grooves 24 opened at both ends of the concave mold 2 for the two ends of the flat wire 6 to be bent and formed.

[0041] For the convenience of description, the four sides of the flat wire 6 are numbered as a first side 61 , a second side 62 , a third side 63 and a fourth side 64 , wherein the first side 61 and the third side 63 are opposite sides, and the second side 62 and the fourth side 64 are opposite sides.

[0042] The bending and forming area includes a first forming surface 111 , a second forming surface 121 , a third forming surface 221 and a fourth forming surface 211 for bending the first side surface 61 , the second side surface 62 , the third side surface 63 and the fourth side surface of the flat wire respectively.

[0043] The first molding surface 111 and the second molding surface 121 are arranged on the convex mold 1, and the third molding surface 221 and the fourth molding surface 211 are arranged on the concave mold 2; and the first molding surface 111 and the third molding surface 221 are arranged opposite to each other, and the second molding surface 121 and the fourth molding surface 211 are arranged opposite to each other.

[0044] refer to Figure 5 , which is a simplified structural diagram of a convex mold 1 and a concave mold 2. The convex mold 1 includes a lower convex molding block 11 and an upper convex molding block 12 protruding from the lower convex molding block 11. The concave mold 2 includes an upper concave molding block 22 and a lower concave molding block 21 protruding from the upper concave molding block 22.

[0045] The stepped surfaces of the upper convex molding block 12 and the lower concave molding block 21 are the second molding surface 121 and the fourth molding surface 211 which are opposite to each other. The second molding surface 121 and the fourth molding surface 211 are arched surfaces with matching shapes. The shapes of the arched surfaces can be referred to Figure 7 .

[0046] The convex mold 1 and the concave mold 2 are both step-shaped molding blocks, and their step surfaces are arranged opposite to each other. The flat wire 6 is placed on the fourth molding surface 211, and then the convex mold 1 is driven downward by the first lifting mechanism, and the second side surface 62 and the fourth side surface 64 of the flat wire 6 are in close contact with the second molding surface 121 and the fourth molding surface 211 respectively to press out a U-shaped bottom.

[0047] Reference again Figure 1The sides of the upper convex forming block 12 and the upper concave forming block 22 facing each other are both curved surfaces with wavy curves. The sides of the lower convex forming block 11 and the lower concave forming block 21 facing each other are respectively consistent with the outer contours of the curved surfaces of the upper convex forming block 12 and the upper concave forming block 22;

[0048] The first molding surface 111 is the arc surface of the lower convex molding block 11, and the third molding surface 221 is the arc surface of the upper concave molding block 22. It is convenient to mold the first side surface 61 and the third side surface 63 of the flat wire 6 into a wave-shaped arc surface.

[0049] It is worth mentioning that the shapes of the first molding surface 111 and the third molding surface 221 are not completely consistent with the shapes of the first side surface 61 and the third side surface 63, but have a certain excess design. This is due to the rebound of the copper wire itself. The flat wire 6 punched by the mold that completely matches the shape of the flat wire 6 often cannot reach the required shape, resulting in difficulty in inserting the wire, and affecting the subsequent twisting process. The mold designed completely in the shape of the mold is difficult to process, and the processing of chamfers and other places requires manual polishing, which increases labor costs, and the size of manual polishing cannot guarantee the required size requirements, and the uncontrollable risk is high.

[0050] The shapes of the convex mold 1 and the concave mold 2 in this solution are drawn by 3D drawing software. The general steps of drawing are: the projection of the first side 61 or the third side 63 of the flat wire 6 on the plane is a wavy curved curve, the curve is divided into two left and right sections, the left and right sections of the curve are rotated respectively, so that the redrawn curve has an offset angle relative to the projected curve. Similarly, the projection of the second side 62 or the fourth side 64 of the projected flat wire 6 is roughly a U-shaped curve, and the redrawn curve also has an offset angle relative to the projected curve.

[0051] refer to Figure 1 and Figure 6 The bottom surface 213 of the bending groove 24 and the fourth molding surface 211 of the concave molding block 21 form a continuous smooth surface, and the connecting portion 212 of the bottom surface 213 and the fourth molding surface 211 is provided with an arc chamfer. The shape of the formed flat wire 6 is a line extending along the fourth molding surface 211 and the bottom surface 213.

[0052] refer to Figure 6-7 , both ends of the second molding surface 121 are provided with arc-shaped chamfered portions 7; both ends of the upper concave molding block 22 near the bending groove 24 are provided with arc-shaped chamfered portions 7; the four corners of the lower concave molding block 21 located in the bending molding area are provided with arc-shaped chamfered portions 7. The structure is optimized, and multiple edges are chamfered to avoid damage to the copper wire caused by sharp edges during the mold closing process. If the chamfered portion 7 is not designed, there will actually be a bulge after the mold is closed, which will damage the copper wire during the molding process.

[0053] refer to Figure 2-3 The bending module 5 includes a pressing wheel 51 and a mounting block 52 arranged on both sides of the concave mold 2. The mounting block 52 is slidably connected to the second mounting frame 23 through the second guide rail 231; the pressing wheel 51 is rotatably connected to the mounting block 52 through an axis. The curved surface of the pressing wheel 51 contacts the copper wire when in use, and the copper wire can be bent along the vertical grooves on both sides of the bending groove 24 by moving downward. In addition, the pressing wheel 51 can rotate, so the friction mode of contact between it and the copper wire is rolling friction rather than sliding friction, which can reduce friction and thus reduce friction damage to the copper wire.

[0054] The first mounting frame 13 is fixedly connected with a wire-passing assembly block 4 arranged on both sides of the convex mold 1; the wire-passing assembly block 4 includes a support plate 41 and a cross plate 42 arranged in parallel and connected to each other, and a mounting groove is formed between the support plate 41 and the cross plate 42. When in use, the two ends of the copper wire are respectively inserted into the two mounting grooves.

[0055] The working principle of the utility model is as follows: during forming, both sides of the copper wire are inserted into the mounting grooves of the wire assembly block 4, and the copper wire is located between the convex mold 1 and the concave mold 2. The cylinder first drives the concave mold 2 to move relative to the convex mold 1, and the impact force makes the copper wire and the mold closely contact and form. In this stamping, the first molding surface 111 of the convex mold 1 and the third molding surface 221 of the concave mold 2 respectively mold the first side surface 61 and the third side surface 63 of the copper wire into a wavy curved surface.

[0056] Secondly, due to the stamping in the previous step, the copper wire contacts the step surface of the concave mold 2, and the first lifting mechanism drives the convex mold 1 to press downward, so that the copper wire is pressed into a flat wire on the step surfaces of the convex mold 1 and the concave mold 2. That is, the second molding surface 121 of the convex mold 1 and the fourth molding surface 211 of the concave mold 2 respectively mold the second side surface 62 and the fourth side surface 64 of the copper wire.

[0057] Finally, the bending module 5 is in close contact with the copper wire, and the second lifting mechanism drives the bending module 5 to move downward along the vertical groove 14, so that the copper wire moves along the bending groove 24 along with the movement of the bending module 5, thereby being bent into a U-shape.

[0058] In summary, the flat wire 6 can be formed at one time on the same device through the above steps, which not only saves the cost of purchasing equipment, but also greatly shortens the transportation time between different processes and improves production efficiency.

Claims

1. A motor flat wire card forming device, characterized in that: The invention comprises a convex mold (1) and a concave mold (2) arranged opposite to each other, a cylinder driving the concave mold (2) to move relative to the convex mold (1), a first lifting mechanism driving the convex mold (1) to perform lifting movement, a bending module (5), and a second lifting mechanism driving the bending module (5) to perform lifting movement; the convex mold (1) and the concave mold (2) both comprise a press-bending molding area and a bending molding area; The bending and forming area comprises vertical grooves (14) provided at both ends of the convex mold (1) for the bending module (5) to pass vertically, and bending grooves (24) provided at both ends of the concave mold (2) for the two ends of the flat wire (6) to be bent and formed; The bending and forming area comprises a first forming surface (111), a second forming surface (121), a third forming surface (221) and a fourth forming surface (211) respectively used for bending a first side surface (61), a second side surface (62), a third side surface (63) and a fourth side surface of the flat wire; The first molding surface (111) and the second molding surface (121) are arranged on the convex mold (1), and the third molding surface (221) and the fourth molding surface (211) are arranged on the concave mold (2); and the first molding surface (111) and the third molding surface (221) are arranged opposite to each other, and the second molding surface (121) and the fourth molding surface (211) are arranged opposite to each other.

2. The motor flat wire hairpin forming device according to claim 1, characterized in that: The convex mold (1) comprises a lower convex molding block (11) and an upper convex molding block (12) protruding from the lower convex molding block (11); the concave mold (2) comprises an upper concave molding block (22) and a lower concave molding block (21) protruding from the upper concave molding block (22); The step surfaces of the upper convex molding block (12) and the lower concave molding block (21) are respectively the second molding surface (121) and the fourth molding surface (211) opposite to each other; the second molding surface (121) and the fourth molding surface (211) are arched surfaces with mutually matching shapes.

3. The motor flat wire clip forming device according to claim 2, characterized in that: The sides of the upper convex molding block (12) and the upper concave molding block (22) facing each other are both arc-shaped surfaces that are curved in a wave shape; the sides of the lower convex molding block (11) and the lower concave molding block (21) facing each other are respectively consistent with the outer contours of the arc-shaped surfaces of the upper convex molding block (12) and the upper concave molding block (22); The first molding surface (111) is the arcuate surface of the lower convex molding block (11); and the third molding surface (221) is the arcuate surface of the upper concave molding block (22).

4. The motor flat wire hairpin forming device according to claim 2, characterized in that: The bottom surface (213) of the bending groove (24) and the fourth molding surface (211) of the concave molding block (21) form a continuous smooth surface, and the connecting portion (212) between the bottom surface (213) and the fourth molding surface (211) is provided with an arc chamfer.

5. The motor flat wire hairpin forming device according to claim 2, characterized in that: Both ends of the second molding surface (121) are provided with arc-shaped chamfered portions (7); both ends of the upper concave molding block (22) close to the bending groove (24) are provided with arc-shaped chamfered portions (7); and the four corners of the lower concave molding block (21) located in the bending molding area are provided with arc-shaped chamfered portions (7).

6. The motor flat wire hairpin forming device according to claim 1, characterized in that: The molding device also includes a bottom plate (3), on which a first mounting frame (13) and a second mounting frame (23) are arranged; the second mounting frame (23) is slidably connected to the bottom plate (3) via a horizontal guide rail (31), and the first mounting frame (13) is fixedly connected to the bottom plate (3); The convex mold (1) is slidably connected to a first mounting frame (13) via a first guide rail (131); the concave mold (2) is fixedly connected to a second mounting frame (23); and the second mounting frame (23) is connected to a cylinder.

7. The motor flat wire hairpin forming device according to claim 6, characterized in that: The bending module (5) comprises a pressing wheel (51) and a mounting block (52) arranged on both sides of the concave mold (2); the mounting block (52) is slidably connected to the second mounting frame (23) via a second guide rail (231); and the pressing wheel (51) is rotationally connected to the mounting block (52) via a shaft.

8. The motor flat wire hairpin forming device according to claim 6, characterized in that: The first mounting frame (13) is fixedly connected to a wire-passing assembly block (4) arranged on both sides of the convex mold (1); the wire-passing assembly block (4) comprises a supporting plate (41) and a cross plate (42) arranged in parallel and connected to each other, and a mounting groove is formed between the supporting plate (41) and the cross plate (42), and when in use, the two ends of the copper wire are respectively inserted into the two mounting grooves.

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