Flat wire motor winding hairpin high-flexibility forming equipment

Abstract

The utility model discloses a flat wire motor winding hairpin high-flexibility forming device, which relates to the technical field of 3D forming equipment and comprises an annular conveying line, a copper wire cross-layer bending forming unit is arranged at the upper end of the annular conveying line, and a high-voltage testing unit is arranged at the upper end of the annular conveying line. A magnetic suspension stator coil unit is arranged at the lower end of the annular conveying line, a copper wire D arc-shaped bend forming unit is arranged on one side of the annular conveying line, and a copper wire clamping trolley is arranged at the upper end of the trolley unlocking unit. According to the hairpin high-flexibility forming equipment for the winding of the flat wire motor, copper wires can be driven to be transported and processed, high-speed and high-flexibility processing can be carried out on the copper wires of different wire types by adopting a servo module for the staggered layer and D splitting and pulling module, and the processing of flat wires of different wire types can be completed by an equipment manufacturer only by adding a program formula, so that the production cost is reduced, and the production efficiency is improved. And the troubles of remodeling and coping caused by mold processing are avoided.

Description

Technical Field

[0001] The utility model relates to the technical field of 3D molding equipment, in particular to a high-flexibility molding equipment for a flat wire motor winding clip. Background Art

[0002] At present, new energy vehicles are developing vigorously around the world, among which the drive motor is one of the core components of new energy vehicles. The winding wire cross-section of the flat wire motor is a quadrilateral, which can greatly improve the motor slot fill rate compared with ordinary round wire motors, and then improve the power density of the motor. At present, flat wire winding motors are widely used in the drive systems of new energy vehicles.

[0003] During the manufacturing process of the stator assembly of a flat wire motor, the winding needs to be made into a hairpin shape and installed into the stator by insertion. Therefore, this type of flat wire motor is also called a hairpin motor. The hairpin forming process and equipment are important process links in the motor stator manufacturing process. The traditional hairpin forming method mostly uses a one-time stamping method of the mold. The disadvantages of using mold stamping are:

[0004] First: the mold manufacturing cost is high and the flexibility is poor: each wire type requires a mold, and a stator product requires more than ten sets of molds. Once the product is changed, all the molds must be changed. Depending on the design of the product, multiple sets of molds are required to produce one product. The cost of changing the mold is high, and manual changing is time-consuming and labor-intensive. Second: the paint on the surface of the copper wire is easily damaged during the stamping process. The damage to the paint will affect the insulation performance of the winding, and then affect the quality of the product, which has a certain adverse effect on people's use process. In order to solve the shortcomings of the existing technology, we propose a high-flexibility forming equipment for flat wire motor winding clips. Utility Model Content

[0005] The main purpose of the utility model is to provide a high-flexibility forming device for flat wire motor winding clips, which can effectively solve the problems in the background technology.

[0006] In order to achieve the above purpose, the technical solution adopted by the utility model is:

[0007] A highly flexible forming device for flat wire motor winding card issuance comprises a circular conveyor line and a trolley unlocking unit. The upper end of the circular conveyor line is provided with a copper wire cross-layer bending forming unit, the upper end of the circular conveyor line is provided with a high-voltage testing unit, the lower end of the circular conveyor line is provided with a magnetic suspension stator coil unit, one side of the circular conveyor line is provided with a copper wire D-arc bending forming unit, and the upper end of the trolley unlocking unit is provided with a copper wire clamping trolley.

[0008] Preferably, the copper wire D arc bending unit includes a rotating axis R axis, a second cylinder, a seventh air claw, a servo screw Y axis and a servo screw X axis, the lower end of the servo screw X axis is provided with a rotating axis R axis, the front side of the rotating axis R axis is provided with a second cylinder, a seventh air claw is provided on one side of the second cylinder, and a servo screw Y axis is provided on one side of the seventh air claw.

[0009] Preferably, the high-voltage testing unit includes a servo screw Z axis, a rotating servo R axis, a carbon brush and a sixth air gripper, the lower end of the rotating servo R axis is provided with a carbon brush, a sixth air gripper is provided on one side of the carbon brush, and the lower end of the sixth air gripper is provided with a servo screw Z axis.

[0010] Preferably, the trolley unlocking unit includes an unlocking cylinder.

[0011] Preferably, the copper wire cross-layer bending forming unit includes a first servo screw module, a second servo screw module, a first air gripper, a second air gripper, a third air gripper, a fourth air gripper and a fifth air gripper. The first air gripper, the second air gripper, the third air gripper, the fourth air gripper and the fifth air gripper are all staggered, including: fixed leg staggered, roof staggered, free leg staggered and roof reverse staggered.

[0012] Preferably, the copper wire clamping trolley is a magnetic levitation trolley.

[0013] Beneficial effects

[0014] Compared with the prior art, the present invention has the following beneficial effects:

[0015] 1. In the utility model, the annular conveyor line and the copper wire D-arc bending unit are provided to drive the copper wire for transportation and processing. The staggered layer and D-splitting module adopts a servo module to perform high-speed and high-flexibility processing on copper wires of different line types. Equipment manufacturers only need to increase the program formula to complete the processing of flat wires of different line types, avoiding the trouble of changing the mold and grinding caused by mold processing.

[0016] 2. In the utility model, the copper wire D-shaped arc bending unit and other structures are set up, and the copper wire is clamped on the copper wire clamping trolley. Through the combination of multi-position positioning and stopping of the magnetic suspension mover and the forming claws installed on the servo screw module, different program formulas are combined to highly flexibly meet the products of different line types and different staggered depths, thereby increasing the practicality of the device. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic diagram of the overall structure of the utility model;

[0018] Figure 2 This is a schematic diagram of the combined structure of the copper wire cross-layer bending unit of the present invention;

[0019] Figure 3 This is a schematic diagram of the combined structure of the first air gripper and the second air gripper of the utility model;

[0020] Figure 4 This is a schematic diagram of the combined structure of the copper wire D arc bending unit of the present invention;

[0021] Figure 5 It is a schematic diagram of the combined structure of the high-voltage test unit of the utility model.

[0022] In the figure: 1. Annular conveyor line; 2. Copper wire clamping trolley; 3. Copper wire cross-layer bending unit; 4. Copper wire 3D arc bending unit; 5. High-voltage testing unit; 6. Trolley unlocking unit; 7. Magnetic levitation stator coil unit; 310. First air gripper; 311. Second air gripper; 312. Third air gripper; 313. Fourth air gripper; 314. Fifth air gripper; 54. Servo screw Z-axis; 51. Rotary servo R-axis; 52. Carbon brush; 53. Sixth air gripper; 31. First servo screw module; 32. Second servo screw module; 41. Rotary axis R-axis; 42. Second cylinder; 43. Seventh air gripper; 44. Servo screw X-axis; 45. Servo screw Y-axis. DETAILED DESCRIPTION

[0023] In order to make the technical means, creative features, objectives and effects achieved by the present invention easier to understand, the present invention is further described below in conjunction with specific implementation methods.

[0024] like Figure 1 As shown, a copper wire cross-layer bending unit 3 is provided at the upper end of the circular conveyor line 1, a high-voltage testing unit 5 is provided at the upper end of the circular conveyor line 1, a magnetic levitation stator coil unit 7 is provided at the lower end of the circular conveyor line 1, and a copper wire 3D arc bending unit 4 is provided on one side of the circular conveyor line 1.

[0025] like Figure 2 As shown, the copper wire cross-layer bending forming unit 3 includes a first air gripper 3310, a second air gripper 3311, a third air gripper 312, a fourth air gripper 313 and a fifth air gripper 314, and the output ends of the first air gripper 3310, the second air gripper 3311, the third air gripper 312, the fourth air gripper 313 and the fifth air gripper 314 are equipped with clamps with different arcs.

[0026] like Figure 3 As shown, the first air gripper 3310, the second air gripper 3311, the third air gripper 312, the fourth air gripper 313 and the fifth air gripper 314 are all staggered, including fixed leg staggered, roof staggered, free leg staggered and roof reverse staggered.

[0027] like Figure 4As shown, the copper wire 3D arc bending unit 4 includes a rotating axis R axis 41, a second cylinder 42, a seventh air gripper 43, a servo screw Y axis 45 and a servo screw X axis 44. The servo screw X axis 44 has a rotating axis R axis 41 at the lower end, a second cylinder 42 is provided on the front side of the rotating axis R axis 41, a seventh air gripper 43 is provided on one side of the second cylinder 42, and a servo screw Y axis 45 is provided on one side of the seventh air gripper 43.

[0028] like Figure 5 As shown, the high-voltage test unit 5 includes a servo screw Z-axis 54, a rotating servo R-axis 51, a carbon brush 52 and a sixth air gripper 53. The carbon brush 52 is provided at the lower end of the rotating servo R-axis 51, the sixth air gripper 53 is provided on one side of the carbon brush 52, and the servo screw Z-axis 54 is provided at the lower end of the sixth air gripper 53.

[0029] It should be noted that the present invention is a high-flexibility forming device for flat wire motor winding card. When in use, the copper wire clamping trolley with the copper wire flows into the processing position and stops at the correct processing position according to different line shapes and line widths. The first servo screw module 31 moves to the staggered position in advance, the fifth air claw 314 and the third air claw 312 clamp the copper wire, and the fourth air claw 313 roof staggered clamp clamps the copper wire roof to complete the staggered forming of the copper wire. After all the clamps are opened, the copper wire clamping trolley flows out, and the cycle is repeated in sequence. The copper wire clamping trolley with the staggered copper wire flows into the processing position. When it reaches the processing position, the second cylinder 42 drives the clamp to clamp the fixed leg of the copper wire and the position of the servo screw Y-axis 45. The servo screw X-axis 44, the servo screw Y-axis 45 and the rotating axis R-axis 41 clamp the free leg of the copper wire through the seventh air claw 43, and the trajectory 3D bending is performed according to the trigonometric function formula. Because the three axes: X-axis & Y-axis & R-axis all use servo modules, they can be compatible with 3D arc-shaped copper wire with a shoulder width of 50-130. Through trigonometric functions, the wire forming can bend the copper wire in a geometric arc. Compared with point positioning, the forming of the copper wire is smoother.

[0030] The copper wire clamping trolley brings the copper wire that has completed 3D arc forming to the processing position. The servo screw Z axis 54 drives the sixth air gripper 53 to rise, clamping the copper wire to fix the leg in the paint removal position. The rotating servo R axis 51 drives the carbon brush 52 to wrap around the copper wire to perform a high-voltage power-on test in an arc of about 45° to test the insulation of the copper wire under the high-voltage line. This process is also called a withstand voltage test.

[0031] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The above embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and improvements may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and improvements are intended to fall within the scope of the present invention. The scope of protection claimed in this invention is defined by the appended claims and their equivalents.

Claims

1. A highly flexible forming device for flat wire motor winding carding, comprising a ring conveyor line (1) and a trolley unlocking unit (6), characterized in that: The upper end of the annular conveyor line (1) is provided with a copper wire cross-layer bending unit (3), the upper end of the annular conveyor line (1) is provided with a high-voltage testing unit (5), the lower end of the annular conveyor line (1) is provided with a magnetic suspension stator coil unit (7), one side of the annular conveyor line (1) is provided with a copper wire 3D arc bending unit (4), and the upper end of the trolley unlocking unit (6) is provided with a copper wire clamping trolley (2).

2. The high-flexibility forming equipment for flat wire motor winding clips according to claim 1, characterized in that: The copper wire 3D arc bending unit (4) comprises a rotating shaft R-axis (41), a second air cylinder (42), a seventh air claw (43), a servo screw Y-axis (45) and a servo screw X-axis (44), wherein the rotating shaft R-axis (41) is provided at the lower end of the servo screw X-axis (44), the second air cylinder (42) is provided at the front side of the rotating shaft R-axis (41), the seventh air claw (43) is provided on one side of the second air cylinder (42), and the servo screw Y-axis (45) is provided on one side of the seventh air claw (43).

3. The high-flexibility forming equipment for flat wire motor winding clips according to claim 1, characterized in that: The high-voltage test unit (5) comprises a servo screw Z-axis (54), a rotary servo R-axis (51), a carbon brush (52) and a sixth air gripper (53), wherein the carbon brush (52) is provided at the lower end of the rotary servo R-axis (51), the sixth air gripper (53) is provided on one side of the carbon brush (52), and the servo screw Z-axis (54) is provided at the lower end of the sixth air gripper (53).

4. The high-flexibility forming equipment for flat wire motor winding clips according to claim 1, characterized in that: The trolley unlocking unit (6) comprises an unlocking cylinder.

5. The high-flexibility forming equipment for flat wire motor winding clips according to claim 1, characterized in that: The copper wire cross-layer bending forming unit (3) comprises a first servo screw module (31), a second servo screw module (32), a first air gripper (310), a second air gripper (311), a third air gripper (312), a fourth air gripper (313) and a fifth air gripper (314), wherein the first air gripper (310), the second air gripper (311), the third air gripper (312), the fourth air gripper (313) and the fifth air gripper (314) are all arranged in staggered layers, including staggered layers of fixed legs, roof staggered layers, free leg staggered layers and roof reverse staggered layers.

6. The high-flexibility forming equipment for flat wire motor winding clips according to claim 1, characterized in that: The copper wire clamping trolley (2) is a magnetic levitation trolley.

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