Automatic rotor wire forming tool

Abstract

The utility model discloses an automatic forming tool for a rotor coil, and belongs to the technical field of motor rotor manufacturing. The tool comprises an upper die, a lower die, a bending die and a flattening mechanism integrated between the upper die and the lower die. The lower die is provided with a positioning block and a positioning step, and a positioning groove is formed in the positioning step; the upper die is provided with a forming groove defined by pressing blocks. The flattening mechanism comprises an upper flattening block and a lower flattening block which are vertically symmetrical, and 7-shaped flattening grooves are machined in the ends of the flattening mechanism and penetrate through the pressing block and the positioning step to enter the matching groove and the positioning groove correspondingly. When the upper die and the lower die are pressed, the flattening grooves are closed to form a square-shaped forming cavity, and coil bending and wire end flattening are completed synchronously. According to the utility model, the problems of low efficiency and inconsistent size of the existing manual flattening are solved, the synchronous operation of forming and flattening is realized, the production efficiency and the flattening precision are improved, and the installation regularity of the coil and the structural stability of the rotor are ensured.

Description

Technical Field

[0001] The utility model relates to the technical field of motor rotor manufacturing, in particular to an automatic forming tool for synchronously completing a wire end flattening operation during a rotor coil forming process. Background Art

[0002] In the motor rotor manufacturing process, the rotor coil forming is one of the key processes. In the prior art, the rotor coil is usually initially formed (such as a U-shaped bend) by a forming die composed of an upper die and a lower die. Chinese invention patent publication number CN208112462U discloses a rotor coil forming mold comprising an upper mold and a lower mold. The lower mold features a square positioning block with a triangular bent wall at one end. The lower mold has positioning steps along both sides of the positioning block, with arc-shaped positioning grooves on the positioning steps near the side walls of the forming block. The lower mold features a V-shaped bending step along the bending wall of the positioning block, with a convex abutment edge positioned in the middle of the bending step. The upper mold features several pressing blocks arranged to form matching grooves that mate with the positioning blocks. Each pressing block has a pressing groove corresponding to the positioning groove. An inverted V-shaped pressing step is provided on one side of the upper mold, with a concave abutment edge corresponding to the convex abutment edge. When the positioning block engages the pressing groove, the pressing step is spaced apart from the bending step. This allows for rapid positioning and forming of the rotor coil, ensuring high production quality and achieving reliable and convenient forming, thereby improving production efficiency.

[0003] The rotor coil produced using the above structure requires further manual flattening of the open end of the wire to form a flattened portion. This is necessary to meet clearance requirements during assembly of the armature inner layer (to avoid short circuits) and to improve coil rigidity (to reduce centrifugal deformation and vibration during high-speed rotation). However, manual flattening has the following drawbacks:

[0004] 1. Low production efficiency: additional manual operation procedures are required, delaying production progress;

[0005] 2. Poor dimensional consistency: uneven manual flattening force leads to dimensional deviation of the flattened part, which makes the coil prone to irregularity during installation;

[0006] 3. Insufficient structural stability: Inconsistent size of the flattened part may affect the overall operating stability of the rotor.

[0007] Therefore, there is an urgent need for an automated tooling that can synchronously complete wire end flattening during the rotor coil forming process to solve the above problems. Utility Model Content

[0008] In order to solve the above problems, the purpose of this utility model is to provide an automatic forming tool for rotor coils. By integrating a flattening mechanism in the forming mold, the coil forming and the wire end flattening can be completed simultaneously, thereby improving production efficiency, ensuring the consistency of the flattening size, and enhancing the regularity of coil installation and the stability of the rotor structure.

[0009] To achieve the above-mentioned object, the utility model provides the following technical solutions: a rotor coil automatic forming tool, comprising an upper die, a lower die and a bending die; a square-shaped positioning block is convexly provided on the lower die, and positioning steps are provided on both sides of the positioning block of the lower die, and an arc-shaped positioning groove is provided on the positioning step near the side wall of the positioning block; the upper die is provided with a plurality of pressing blocks, and the pressing blocks are arranged to form a forming groove matching the positioning block, and a matching groove corresponding to the positioning groove is provided at the lower end of the pressing block; a flattening mechanism is provided between the upper die and the lower die, and the flattening mechanism includes an upper flattening block and a lower flattening block symmetrically arranged above and below;

[0010] The upper flattening block is detachably mounted on the upper die, and the lower flattening block is detachably mounted on the lower die; an upper flattening groove in the shape of a "7" is provided at the end of the upper flattening block, and a lower flattening groove in the shape of a "7" is provided at the end of the lower flattening block; the upper flattening groove passes through the pressing block and enters the matching groove, and the lower flattening groove passes through the positioning step and enters the positioning groove; when the upper and lower dies are pressed together, the upper flattening groove and the lower flattening groove form a "mouth"-shaped forming cavity;

[0011] The flattening mechanism further comprises an upper slot and a lower slot: the upper die is provided with an upper slot matching the upper flattening block, and the lower section of the upper slot is directly connected to the matching slot; the lower die is provided with a lower slot matching the lower flattening block, and the upper section of the lower slot is directly connected to the positioning slot; after the upper flattening block is inserted into the upper slot, its upper end surface is flush with the upper end surface of the upper die, and the upper end surface of the upper die is in contact with a connecting seat and fixed by bolts; after the lower flattening block is inserted into the lower slot, its lower end surface is flush with the lower end surface of the lower die, and the lower end surface of the lower die is in contact with a base and fixed by bolts;

[0012] The bending die is fixed on a machine frame, the lower die is movably arranged above the bending groove of the bending die through a first cylinder; the upper die is movably arranged above the lower die through a second cylinder.

[0013] Furthermore, the upper flattening block and the lower flattening block have the same structure, both including a flattening block body and a limit block; the limit block is connected to the upper end (or lower end, corresponding to the upper / lower flattening block) of the flattening block body, and the width of the limit block is greater than the width of the flattening block body; the "7"-shaped flattening groove is opened on the other end face of the flattening block body away from the limit block.

[0014] Furthermore, the matching groove of the upper die and the positioning groove of the lower die are fitted together to form a shaping groove when the upper and lower dies are pressed together. The shaping groove is used to constrain the bending path of the copper wire and ensure the forming accuracy of the closed end of the U-shaped coil.

[0015] Furthermore, the bending wall of the positioning block is a triangular structure, which cooperates with the bending groove of the bending die to guide the copper wire to bend into a U shape.

[0016] The beneficial effects of the utility model are:

[0017] 1. Synchronous forming to improve efficiency: By integrating a flattening mechanism between the upper and lower dies, the wire ends are flattened while the coil is being formed, eliminating the manual flattening process and significantly improving production efficiency.

[0018] 2. Consistent size and neat installation: The structural design of the flattening groove ("" shape) and the detachable installation method ensure the uniformity of the flattening force, the stability of the flattening part size, and the neat arrangement of the coils during installation;

[0019] 3. Stable structure and reliable performance: The dimensional consistency of the flattened part reduces centrifugal deformation and vibration during high-speed rotation, and enhances the stability of the rotor's overall structure;

[0020] 4. Strong adaptability: The flattening block can be detachably installed, making it easy to change the flattening slot size according to different coil specifications, and has a wide range of applications.

[0021] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 A perspective view of a specific embodiment of the present utility model;

[0023] Figure 2 An exploded view of a specific embodiment of the present utility model;

[0024] Figure 3 It is a three-dimensional diagram of the flattening mechanism in a specific embodiment of the present invention.

[0025] In the figure, 1. upper die; 2. lower die; 3. bending die; 4. flattening mechanism; 21. positioning block; 211. bending wall; 22. positioning step; 23. positioning groove; 11. pressing block; 12. matching groove; 41. upper flattening block; 411. upper flattening groove; 42. lower flattening block; 421. lower flattening groove; 43. forming cavity; 13. upper slot; 10. connecting seat; 24. lower slot; 31. bending groove; 20. forming groove; 401. pressing block body; 402. limiting block. DETAILED DESCRIPTION

[0026] The present invention is described in detail below through embodiments, which are only used to further illustrate the present invention and should not be construed as limiting the scope of protection of the present invention.

[0027] like Figure 1 — Figure 3 As shown, this embodiment discloses a rotor coil automatic forming tool, including an upper mold 1, a lower mold 2, a bending mold 3 and a flattening mechanism 4.

[0028] The upper surface of the lower die 2 is provided with a square positioning block 21, one end of which is a triangular bending wall 211 (which cooperates with the bending groove 31 of the bending die 3 to guide the copper wire bending). The lower die 2 is provided with positioning steps 22 on both sides of the positioning block 21. The positioning steps 22 are provided with arc-shaped positioning grooves 23 near the side walls of the positioning block 21 (to support the straight segments on both sides of the coil).

[0029] The lower surface of the upper mold 1 is provided with multiple pressing blocks 11, which are arranged to form a forming groove 20 that matches the outer contour of the positioning block 21 (used to constrain the positioning block 21 to ensure alignment of the upper and lower molds), and the lower end of the pressing block 11 is provided with a matching groove 12 corresponding to the positioning groove 23.

[0030] The flattening mechanism 4 includes an upper flattening block 41 and a lower flattening block 42, which are detachably mounted on the upper die 1 and the lower die 2, respectively. The end of the upper flattening block 41 is machined with an upper flattening groove 411 in the shape of a "7", and the end of the lower flattening block 42 is machined with a lower flattening groove 421 in the shape of a "7". The upper flattening groove 411 passes through the pressing block 11 and enters the matching groove 12, and the lower flattening groove 421 passes through the positioning step 22 and enters the positioning groove 23. When the upper and lower dies are pressed together, the upper flattening groove 411 and the lower flattening groove 421 close to form a "mouth"-shaped forming cavity 43 (for flattening the coil wire end).

[0031] The upper flattening block 41 and the lower flattening block 42 have the same structure, both including a pressure block body 401 and a limit block 402; the limit block 402 is connected to the upper end of the pressure block body 401, and the width of the limit block 402 is greater than the width of the pressure block body 401; the "7"-shaped flattening groove is opened on the other end face of the pressure block body 401 away from the limit block.

[0032] The upper mold 1 is provided with an upper slot 13 (matching the upper flattening block 41), the lower section of which extends directly into the mating slot 12. After the upper flattening block 41 is inserted into the upper slot 13, its upper end face is flush with the upper end face of the upper mold 1, and the upper end face of the upper mold 1 abuts the lower end face of a connecting seat 10 and is secured by bolts. Similarly, the lower mold 2 is provided with a lower slot 24 (matching the lower flattening block 42), the upper section of which extends directly into the positioning slot 23. After the lower flattening block 42 is inserted into the lower slot 24, its lower end face is flush with the lower end face of the lower mold 2, and the lower end face of the lower mold 2 abuts the upper end face of a base and is secured by bolts.

[0033] The bending die 3 is fixed to the frame and has a bending groove 31 on its side (which mates with the bending wall 211 of the positioning block 21). The lower die 2 is movably positioned in front of the opening of the bending groove 31 of the bending die 3 via a first cylinder, and the upper die 1 is movably positioned above the lower die 2 via a second cylinder.

[0034] Workflow:

[0035] 1. Initial state: Lower die 2 is located in front of bending die 3, upper die 1 is located above lower die 2, and the straight section of the coil copper wire is placed on the bending wall 211 of the positioning block 21 and the positioning groove 23 of the positioning step 22;

[0036] 2. Press Bending: The first cylinder drives the lower die 2 forward, inserting the positioning block 21 into the bending groove 31 of the press bending die 3. The copper wire is bent into a U-shape along the bending wall 211, with the straight sections on both sides resting on the positioning groove 23.

[0037] 3. Pressing and Flattening: The second cylinder drives the upper die 1 downward, pressing it against the lower die 2. At this point, the mating groove 12 and the positioning groove 23 align to form a fixed groove (constraining the U-shaped closed end). Simultaneously, the upper flattening groove 411 and the lower flattening groove 421 close to form a "mouth" shape, forming the cavity 43, flattening the wire end of the U-shaped coil into a block.

[0038] 4. Reset and remove the component: The second cylinder drives the upper die 1 to reset, and the first cylinder drives the lower die 2 to reset, and remove the formed rotor coil (including the flattened wire end).

[0039] Such tooling can realize automatic forming and simultaneously obtain the coil of the flattened part, reducing the number of working steps and improving production efficiency.

[0040] After adopting the above technical solution, the following effects are achieved:

[0041] 1. Synchronous forming to improve efficiency: By integrating a flattening mechanism between the upper and lower dies, the wire ends are flattened while the coil is being formed, eliminating the manual flattening process and significantly improving production efficiency.

[0042] 2. Consistent size and neat installation: The structural design of the flattening groove ("" shape) and the detachable installation method ensure the uniformity of the flattening force, the stability of the flattening part size, and the neat arrangement of the coils during installation;

[0043] 3. Stable structure and reliable performance: The dimensional consistency of the flattened part reduces centrifugal deformation and vibration during high-speed rotation, and enhances the stability of the rotor's overall structure;

[0044] 4. Strong adaptability: The flattening block can be detachably installed, making it easy to change the flattening slot size according to different coil specifications, and has a wide range of applications.

Claims

1. A rotor wire automatic forming tool, comprising an upper die (1), a lower die (2) and a bending die (3); a square-shaped positioning block (21) is convexly provided on the lower die (2), positioning steps (22) are provided on both sides of the positioning block (21), and an arc-shaped positioning groove (23) is provided on the positioning step (22) near the side wall of the positioning block (21); the upper die (1) is provided with a plurality of pressing blocks (11), the pressing blocks (11) are arranged to form a forming groove (20) matching the positioning block (21), and a matching groove (12) corresponding to the positioning groove (23) is provided at the lower end of the pressing block (11), characterized in that: A flattening mechanism (4) is provided between the upper die (1) and the lower die (2), the flattening mechanism (4) comprising an upper flattening block (41) and a lower flattening block (42) symmetrically arranged in an upper and lower direction; the upper flattening block (41) is detachably mounted on the upper die (1), and the lower flattening block (42) is detachably mounted on the lower die (2); an upper flattening groove (411) in the shape of a "7" is provided at the end of the upper flattening block (41), and a lower flattening groove (421) in the shape of a "7" is provided at the end of the lower flattening block (42); the upper flattening groove (411) passes through the pressing block (11) and enters the matching groove (12), and the lower flattening groove (421) passes through the positioning step (22) and enters the positioning groove (23); when the upper and lower dies are pressed together, the upper flattening groove (411) and the lower flattening groove (421) form a "mouth"-shaped forming cavity (43).

2. The rotor wire automatic forming tool according to claim 1, characterized in that: The flattening mechanism (4) further comprises an upper slot (13) and a lower slot (24); the upper die (1) is provided with an upper slot (13) matching the upper flattening block (41), and the lower section of the upper slot (13) is directly connected to the matching slot (12); the lower die (2) is provided with a lower slot (24) matching the lower flattening block (42), and the upper section of the lower slot (24) is directly connected to the positioning slot (23); after the upper flattening block (41) is inserted into the upper slot (13), its upper end face is flush with the upper end face of the upper die (1), and the upper end face of the upper die (1) is fitted with a connecting seat (10) and fixed by bolts; after the lower flattening block (42) is inserted into the lower slot (24), its lower end face is flush with the lower end face of the lower die (2), and the lower end face of the lower die (2) is fitted with a base and fixed by bolts.

3. The rotor wire automatic forming tool according to claim 1, characterized in that: The upper flattening block (41) and the lower flattening block (42) have the same structure, both comprising a flattening block body (401) and a limiting block (402); the limiting block (402) is connected to the upper end of the flattening block body (401), and the width of the limiting block (402) is greater than the width of the flattening block body (401); the "7"-shaped flattening groove is provided on the other end face of the flattening block body (401) away from the limiting block.

4. The rotor wire automatic forming tool according to claim 1, characterized in that: The matching groove (12) of the upper die (1) and the positioning groove (23) of the lower die (2) fit together to form a shaping groove when the upper and lower dies are pressed together. The shaping groove is used to constrain the bending path of the copper wire.

5. The rotor wire automatic forming tool according to claim 1, characterized in that: The bending wall (211) of the positioning block (21) is a triangular structure, and cooperates with the bending groove (31) of the bending die (3) to guide the copper wire to bend into a U shape.

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