Motor stator hairpin type flat wire forming machine

Abstract

The utility model relates to the technical field of motor production, in particular to a motor stator hairpin type flat wire forming machine which comprises a mounting frame. The lower die is provided with a first forming surface, and a feeding hole is formed in the side of the first forming surface; the upper die is provided with a second forming surface, and the second forming surface and the first forming surface are oppositely arranged and matched with each other; the electric cylinder is connected with the side, deviating from the first forming surface, of the lower die and drives the first forming surface to move towards the direction matched with the second forming surface; the air cylinder is connected with the side face of the upper die and drives the upper die to move in the direction perpendicular to the first forming face. The servo motor is used for controlling the electric cylinder to move; the second forming face is provided with a U-shaped limiting block, the opening direction of the limiting block is consistent with the length direction of the protruding edge of the first forming face, and the limiting block is located on the edge of the second forming face. The hairpin type flat wire forming machine has the effect of relieving the problem that related hairpin type flat wire forming machines are complex in forming step and diverse in mold requirement.

Description

Technical Field

[0001] The present application relates to the field of motor production technology, and in particular to a hairpin-type flat wire forming machine for a motor stator. Background Art

[0002] The motor stator is one of the core components of the motor and generator, and its main function is to generate a magnetic field or carry a coil. In the production process of the motor stator, the manufacture of the stator winding is a key link. Traditional stator winding manufacturing usually uses round coils, but with the development of technology, hairpin-type flat wires have gradually become a new trend in stator winding manufacturing due to their higher filling factor, better heat dissipation performance and lower resistance loss. Hairpin-type flat wires can not only increase the power density of the motor, but also effectively reduce the space occupied by the winding, thereby improving the overall performance of the motor.

[0003] Existing hairpin-type flat wire forming machines generally have the problem of multiple forming steps and various molds when forming flat wires. Traditional equipment usually requires a three-step forming process, first the initial forming of the flat wire, then bending it into a U shape, and finally precise shaping, each step requires a different mold. This not only increases the complexity and cost of the equipment, but also reduces production efficiency. In addition, frequent mold replacement not only increases the difficulty of operation, but may also lead to unstable forming quality due to mold wear or improper installation. In addition, the flat wire after forming is prone to rebound, affecting the accuracy and consistency of its final shape, thereby affecting the assembly quality and performance of the motor stator.

[0004] The related hairpin-type flat wire forming machinery has problems of complex forming steps and diverse mold requirements. Utility Model Content

[0005] In order to alleviate the problems of complex forming steps and diverse mold requirements in related hairpin-type flat wire forming machines, the present application provides a motor stator hairpin-type flat wire forming machine.

[0006] The present application provides a motor stator hairpin flat wire forming machine adopts the following technical solution:

[0007] A hairpin-type flat wire forming machine for a motor stator, comprising:

[0008] Mounting frame;

[0009] A lower die, wherein the lower die is provided with a first molding surface, the first molding surface is concave inwardly and presents a convex ridge shape, and a feed port is provided on the side of the first molding surface, and one side of the lower die is slidably connected with the mounting frame through a sliding guide rail;

[0010] An upper mold, wherein the upper mold is provided with a second molding surface, the second molding surface is arranged opposite to the first molding surface and cooperates with each other, and a side of the upper mold away from the second molding surface is slidably connected to the mounting frame through a sliding guide rail;

[0011] An electric cylinder connected to a side of the lower mold away from the first molding surface, driving the first molding surface to move in a direction of matching with the second molding surface;

[0012] A cylinder connected to a side surface of the upper mold to drive the upper mold to move in a direction perpendicular to the first molding surface;

[0013] A servo motor, the servo motor is connected to the electric cylinder and is used to control the movement of the electric cylinder;

[0014] The second molding surface is provided with a limiting block, which is U-shaped, with an opening direction consistent with the length direction of the concave ridge of the first molding surface, and is located at the edge of the second molding surface.

[0015] Optionally, a slider and an adjustment bracket are provided between the lower mold and the sliding guide rail, the lower mold is fixed on the adjustment bracket, the adjustment bracket and the slider are detachably connected to achieve fine adjustment of the relative position, and the slider is slidably connected to the sliding guide rail.

[0016] Optionally, the adjusting bracket is provided with a plurality of rows of positioning holes, and the positioning holes are arranged at equal intervals, and are used to adjust the relative position of the adjusting bracket and the sliding block.

[0017] Optionally, each of the sliding guide rails includes two sliding rails arranged in parallel.

[0018] Optionally, a workbench is further provided at the bottom of the mounting frame, and the workbench includes a support plate and a storage cabinet.

[0019] Optionally, a reinforcing bracket is provided at the bottom of the workbench, and the reinforcing bracket is provided at the four corners of the workbench.

[0020] Optionally, the workbench is provided with control buttons and a working status display, both of which are arranged on the supporting plate.

[0021] The present application uses a lower mold with a first molding surface and an upper mold with a second molding surface, and the lower mold and the upper mold are driven by electric cylinders and air cylinders respectively. The first molding surface of the lower mold is concave and convex, and cooperates with the concave second molding surface of the upper mold to achieve precise molding of the flat wire. Through the movement in two directions combined with the cooperation of the molding surfaces, the initial molding, bending and shaping of the flat wire can be completed in one operation, which significantly simplifies the molding steps and improves production efficiency.

[0022] In order to further improve the molding accuracy and stability, the present application sets a U-shaped limit block on the second molding surface. The opening direction of the limit block is consistent with the length direction of the concave ridge of the first molding surface, which effectively limits the position of the copper material during the molding process and prevents it from shifting, thereby ensuring that the flat wire will not rebound after molding, ensuring product quality.

[0023] In addition, the present application designs an adjustment bracket between the lower die and the sliding guide rail. The adjustment bracket is provided with multiple rows of equally spaced positioning holes, through which the lower die can be fine-tuned relative to the slider, thereby adjusting the progress of the lower die, improving the adaptability and operational flexibility of the equipment.

[0024] Other parts, such as the parallel slide rails, workbench and the reinforced bracket at the bottom, mainly play an auxiliary role, further improving the overall stability and operational convenience of the equipment. The parallel slide rail design enhances the running stability of the upper and lower molds, the workbench provides an operating platform and storage space, and the reinforced bracket improves the structural stability of the equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is an overall schematic diagram of a motor stator hairpin flat wire forming machine in an embodiment of the present application.

[0026] Figure 2 It is a schematic diagram of the lower mold of a motor stator hairpin flat wire forming machine in an embodiment of the present application.

[0027] Figure 3 It is a schematic diagram of an upper mold of a hairpin-type flat wire forming machine for a motor stator in an embodiment of the present application.

[0028] Figure 4 It is a schematic diagram of the cooperation between the lower die and the upper die of a motor stator hairpin flat wire forming machine in an embodiment of the present application.

[0029] Description of reference numerals:

[0030] 1. Mounting frame; 2. Lower die; 21. First molding surface; 22. Feed port; 3. Upper die; 31. Second molding surface; 32. Limit block; 4. Electric cylinder; 5. Air cylinder; 6. Servo motor; 7. Sliding guide rail; 71. Sliding block; 72. Slide rail; 8. Adjustment bracket; 81. Positioning hole; 9. Workbench; 91. Support plate; 92. Storage cabinet; 93. Reinforcement bracket; 94. Control button; 95. Working status display. DETAILED DESCRIPTION

[0031] The present application is further described in detail below in conjunction with all the accompanying drawings.

[0032] The embodiment of the present application discloses a hairpin-type flat wire forming machine for a motor stator.

[0033] Reference Figure 1 A motor stator hairpin flat wire forming machine includes a workbench 9, a mounting frame 1, a mold and a driving part. The workbench 9 provides a stable support structure for the entire forming machine, which can bear the weight of the entire forming machine and the force generated during operation, providing a basic guarantee for the normal operation of the equipment. The forming machine is lifted to a suitable height to ensure the convenience and stability of operation.

[0034] The mounting frame 1 is used to install the mold and the driving member. It is in an inverted U shape and is firmly set on the workbench 9. The inverted U-shaped structure not only improves the strength and stability of the mounting frame 1, but also provides sufficient space for installing and adjusting the mold and the driving member. The upper plane of the mounting frame 1 is used to install the lower mold 2 and the related sliding guide rail 7 system, while the side surface is used to fix the upper mold 3 and the corresponding driving device.

[0035] The mold includes an upper mold 3 and a lower mold 2. The lower mold 2 is provided with a first molding surface 21, which is concave and convex, and the upper mold 3 is provided with a second molding surface 31, which is arranged opposite to the first molding surface 21 and cooperates with each other. The cooperation between the upper mold 3 and the lower mold 2 can complete multiple steps in a one-step molding process, greatly improving the molding efficiency.

[0036] The driving part includes an electric cylinder 4, an air cylinder 5 and a servo motor 6. The electric cylinder 4 is connected to the lower mold 2 to drive the first molding surface 21 to move in the direction of matching with the second molding surface 31 to achieve preliminary molding. The air cylinder 5 is connected to the upper mold 3 to drive the upper mold 3 to move in a direction perpendicular to the first molding surface 21 to complete the final bending and shaping. The servo motor 6 is used to control the movement of the electric cylinder 4 to ensure the accuracy and consistency during the molding process.

[0037] Specifically, the lower mold 2 is mounted on the top of the inverted U-shape of the mounting frame 1 through a sliding guide rail 7. The sliding guide rail 7 includes a guide rail arranged on the mounting frame 1 and a slider 71 connected to the lower mold 2. The lower mold 2 is fixedly connected with an adjustment bracket 8, and the adjustment bracket 8 is detachably connected to the slider 71. The adjustment bracket 8 is provided with multiple rows of positioning holes 81, and the positioning holes 81 are arranged at equal intervals to form a flexible adjustment system. By connecting the adjustment bracket 8 with the slider 71 using different connecting holes, the fine-tuning function of the lower mold 2 can be achieved. Specifically, different connecting hole positions allow the lower mold 2 to be finely adjusted in the horizontal plane, thereby adjusting the stroke of the lower mold 2 to ensure that the lower mold 2 can be accurately aligned with the upper mold 3. This design greatly improves the adaptability and operational flexibility of the equipment, and can cope with different production requirements and material properties, thereby ensuring the stability of the molding quality.

[0038] A feed port 22 is provided on the side of the lower die 2, and the feed port 22 is specifically used to input straight copper material. The copper material is fed into the molding area between the lower die 2 and the upper die 3 through the feed port 22, ensuring that the copper material always maintains the correct position during the entire molding process. The back of the first molding surface 21 is connected to the electric cylinder 4, which provides the necessary driving force to push the lower die 2 to move toward the upper die 3, so that the copper material is pressed into a U-shaped structure between the molding surfaces. The precise control and powerful driving force of the electric cylinder 4 ensure the efficiency and reliability of the molding process.

[0039] The upper die 3 is connected to the side of the inverted U-shaped mounting frame 1 through another sliding guide rail 7, and is opposite to the first molding surface 21 of the lower die 2, ensuring that the upper die 3 can accurately cooperate with the lower die 2 during the molding process to achieve accurate molding of the copper material. The cylinder 5 is connected to the side of the upper die 3 and acts as a driving device to provide the necessary power to achieve the vertical movement of the upper die 3. The cylinder 5 controls the up and down movement of the upper die 3, so that the upper die 3 can apply appropriate pressure and deformation force during the molding process, thereby completing the final shaping of the copper material.

[0040] A limit block 32 is provided at the edge of the second molding surface 31 of the upper mold 3. The limit block 32 is U-shaped, and the opening direction is consistent with the length direction of the concave ridge of the first molding surface 21. The limit block 32 is used to limit the position of the copper material during the molding process, so that it bends along a predetermined trajectory to prevent it from sliding or shifting, thereby ensuring the position accuracy during the molding process.

[0041] The entire molding process is as follows: First, the straight copper material is filled in from the feed port 22 provided on the side of the lower mold 2 so that it is accurately located in the molding area between the first molding surface 21 and the second molding surface 31. The feed port 22 ensures that the copper material can smoothly enter the molding area and maintain the correct initial position during the entire molding process.

[0042] Then, the electric cylinder 4 starts to work, driving the lower die 2 to move along the sliding guide rail 7 toward the upper die 3. As the lower die 2 gradually approaches the upper die 3, the copper material is subjected to the dual forces of the first molding surface 21 and the second molding surface 31, and begins to undergo plastic deformation, and is gradually pressed into a special U-shaped structure. The concave convex ridge-shaped first molding surface 21 of the lower die 2 and the concave second molding surface 31 of the upper die 3 are precisely matched to ensure that the copper material is formed into an ideal U-shape during this process.

[0043] Then, the cylinder 5 is started to drive the upper die 3 to move downward in the vertical direction. The downward pressing action of the upper die 3 applies further pressure to cause the already formed U-shaped copper material to continue to deform. In particular, the parallel edges of the copper material are bent into the final U-shaped bending structure by the stopper 32. The U-shaped design of the stopper 32 ensures the accuracy of the bending position, so that the formed hairpin flat wire has a consistent shape and size.

[0044] In addition, in this embodiment, each sliding guide rail 7 includes two parallel sliding rails 72 to improve the stability of the sliding guide rail 7 and ensure that the upper mold 3 and the lower mold 2 will not deviate during operation. The arrangement of the parallel sliding rails 72 provides a larger support area, reduces the shaking or displacement that may occur in a single sliding rail 72, and thus ensures the accuracy and consistency of the molding process.

[0045] The workbench 9 is also optimized in this embodiment, specifically including a support plate 91, a storage cabinet 92, a reinforcement bracket 93, a control button 94, and a working status display 95. The support plate 91 is used to support the entire motor stator hairpin flat wire forming machine, providing a solid foundation and a stable operating platform to ensure that the equipment remains stable during operation. The storage cabinet 92 is used to accommodate the cylinder 5 and other auxiliary equipment. By storing these components in the cabinet, not only can the equipment be protected from the influence of the external environment, but also the space can be effectively utilized, making the workbench 9 appear neat and orderly.

[0046] The reinforcing brackets 93 are arranged at the four corners of the workbench 9, in an L-shaped structure, and in contact with the ground. The overall structural stability of the workbench 9 is improved, and various stresses and vibrations generated during the operation of the equipment can be better dispersed and withstood, ensuring the reliability and durability of the equipment during long-term high-intensity work.

[0047] The control buttons 94 and the working status display 95 are both arranged on the support plate 91, which is convenient for the operator to control and monitor the equipment. The control buttons 94 are reasonably arranged and easy to operate, and can quickly start and stop the equipment and adjust the working parameters of the equipment. The working status display 95 displays the operating status and various working parameters of the equipment in real time, helping the operator to understand the working status of the equipment in a timely manner and make necessary adjustments and maintenance.

[0048] The implementation principle of a hairpin-type flat wire forming machine for a motor stator in the embodiment of the present application is as follows:

[0049] The embodiment of the present application realizes one-step forming of the copper material through the relative movement of the lower die 2 and the upper die 3 and the precise drive of the electric cylinder 4 and the air cylinder 5. The lower die 2 is connected to the mounting frame 1 through a sliding guide rail 7 system and is driven by the electric cylinder 4 to move in the horizontal direction; the upper die 3 is connected to the mounting frame 1 through another sliding guide rail 7 system and is driven by the air cylinder 5 to move in the vertical direction. After the copper material enters from the feed port 22, it is first pressed into a U-shaped structure by the forming surface between the lower die 2 and the upper die 3, and then the upper die 3 is pressed down to bend the parallel edges of the U-shaped structure into the final shape. The adjusting bracket 8 and the limit block 32 ensure the forming accuracy, and the parallel slide rails 72 and the reinforced bracket 93 improve the stability and reliability of the equipment, thereby realizing an efficient and stable flat wire forming process.

[0050] The above are all preferred embodiments of the present application, and the protection scope of the present application is not limited thereto. Therefore, any equivalent changes made according to the structure, shape, and principle of the present application should be included in the protection scope of the present application.

Claims

1. A hairpin-type flat wire forming machine for a motor stator, characterized in that: include: Mounting frame (1); A lower mold (2), the lower mold (2) being provided with a first molding surface (21), the first molding surface (21) being concave inwardly and convexly ridged, and a feed port (22) being provided on the side of the first molding surface (21), and one side of the lower mold (2) being slidably connected to the mounting frame (1) via a sliding guide rail (7); An upper mold (3), the upper mold (3) being provided with a second molding surface (31), the second molding surface (31) being arranged opposite to and cooperating with the first molding surface (21), and a side of the upper mold (3) facing away from the second molding surface (31) being slidably connected to the mounting frame (1) via a sliding guide rail (7); An electric cylinder (4), the electric cylinder (4) being connected to a side of the lower mold (2) facing away from the first molding surface (21), and driving the first molding surface (21) to move in a direction to cooperate with the second molding surface (31); A cylinder (5), the cylinder (5) being connected to a side surface of the upper mold (3) and driving the upper mold (3) to move in a direction perpendicular to the first molding surface (21); A servo motor (6), the servo motor (6) being connected to the electric cylinder (4) and used for controlling the movement of the electric cylinder (4); The second molding surface (31) is provided with a limiting block (32), the limiting block (32) is U-shaped, the opening direction is consistent with the length direction of the concave ridge of the first molding surface (21), and is located at the edge of the second molding surface (31).

2. The hairpin-type flat wire forming machine for motor stator according to claim 1, characterized in that: A slider (71) and an adjustment bracket (8) are provided between the lower die (2) and the sliding guide rail (7); the lower die (2) is fixed on the adjustment bracket (8); the adjustment bracket (8) and the slider (71) are detachably connected to achieve fine adjustment of the relative position; and the slider (71) is slidably connected to the sliding guide rail (7).

3. The hairpin-type flat wire forming machine for motor stator according to claim 2, characterized in that: The adjusting bracket (8) is provided with a plurality of rows of positioning holes (81), and the positioning holes (81) are arranged at equal intervals and are used to adjust the relative position of the adjusting bracket (8) and the sliding block (71).

4. The hairpin-type flat wire forming machine for motor stator according to claim 1, characterized in that: Each of the sliding guide rails (7) comprises two sliding rails (72) arranged in parallel.

5. The hairpin-type flat wire forming machine for motor stator according to claim 1, characterized in that: A workbench (9) is also provided at the bottom of the mounting frame (1), and the workbench (9) comprises a support plate (91) and a storage cabinet (92).

6. The hairpin-type flat wire forming machine for motor stator according to claim 5, characterized in that: A reinforcing bracket (93) is provided at the bottom of the workbench (9), and the reinforcing bracket (93) is arranged at the four corners of the workbench (9).

7. The hairpin-type flat wire forming machine for motor stator according to claim 5, characterized in that: The workbench (9) is provided with a control button (94) and a working status display (95), both of which are arranged on the support plate (91).

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