New energy round wire motor stator wire inserting production tool

Abstract

The utility model relates to a new energy round wire motor stator coil inserting production tool which comprises a positioning device which comprises a product bearing base, a middle connecting ring installed on the top of the product bearing base and an upper connecting ring fixed to the top of the middle connecting ring. The product bearing base is annular and is used for stably supporting the whole tool, the middle connecting ring is used for connecting and supporting an upper structure, and the upper connecting ring is connected with the middle connecting ring to form a stable frame structure so as to accurately install a stator to be inserted with a wire. And meanwhile, the damage to a round wire insulating layer is reduced, so that the requirements of new energy automobiles on high-performance and large-scale production of motors are met.

Description

Technical Field

[0001] This utility model relates to the field of stator winding production for new energy round wire motors, specifically a tooling for stator winding production of new energy round wire motors. Background Technology

[0002] The stator of a new energy round wire motor is a key component of the drive system of new energy vehicles. The quality of its wire insertion directly affects the motor's performance, such as power density, efficiency, and reliability. The function of the insertion fixture is to accurately and efficiently insert the round wire into the stator slots.

[0003] However, the following drawbacks exist in the traditional production process of stator winding for new energy round wire motors:

[0004] Limited spatial movement: Traditional wiring solutions often face the problem of inconvenient spatial movement during the production process, which limits the improvement of production efficiency.

[0005] Poor integration between automation and manual assembly: Traditional wiring solutions have significant shortcomings in the integration between automated production and manual assembly, which can lead to production interruptions and increase additional time and costs.

[0006] High labor input: Traditional wire embedding solutions require a significant labor force, especially when high wire embedding precision is required. This not only increases labor costs but also leads to inconsistent product quality due to human factors.

[0007] High product damage rate: Traditional winding solutions are prone to damaging the stator or round wire during operation, thus affecting the product yield.

[0008] Unstable performance and short lifespan: Traditional winding fixtures may suffer from unstable performance and a relatively short lifespan due to design or material issues. This increases maintenance costs and replacement frequency, impacting production efficiency and cost control.

[0009] Inconvenient maintenance: Traditional winding fixtures have design flaws that make maintenance complex and time-consuming. This can easily lead to extended production downtime and affect overall production efficiency.

[0010] Therefore, we propose a production tooling for stator winding of new energy round wire motors to improve the accuracy and efficiency of stator winding of round wire motors, while reducing damage to the insulation layer of the round wire, so as to meet the requirements of new energy vehicles for high performance and large-scale production of motors. Utility Model Content

[0011] The purpose of this utility model is to overcome the shortcomings of existing technologies, adapt to practical needs, and provide a new energy round wire motor stator winding production fixture to solve the following problems: Limited space movement: Traditional winding solutions often face the problem of inconvenient space movement during production, limiting the improvement of production efficiency. Poor integration between automation and manual assembly: Traditional winding solutions have significant shortcomings in the integration between automated production and manual assembly, leading to production interruptions and increased additional time and costs. High labor input: Traditional winding solutions require a large labor input, especially when high winding precision is required. This not only increases labor costs but also leads to unstable product quality due to human factors. High product damage rate: Traditional winding solutions are prone to damaging the stator or round wire during operation, thus affecting product yield. Unstable performance and short lifespan: Traditional winding fixtures may have unstable performance and a relatively short lifespan due to design or material problems. This increases maintenance costs and replacement frequency, affecting production efficiency and cost control. Inconvenient maintenance: Traditional winding fixtures may have design deficiencies, making the maintenance process complex and time-consuming. This easily leads to prolonged production interruptions, affecting overall production efficiency.

[0012] To achieve the objectives of this utility model, the technical solution adopted is as follows: A production fixture for stator winding of a new energy round wire motor is designed, including a positioning device.

[0013] The positioning device includes a product receiving base, a central connecting ring installed on the top of the product receiving base, and an upper connecting ring fixed to the top of the central connecting ring.

[0014] The product's support base is ring-shaped, used to stably support the entire tooling. The middle connecting ring is used to connect and support the upper structure. The upper connecting ring is connected to the middle connecting ring to form a stable frame structure for precise installation of the stator to be embedded.

[0015] Preferably, the upper connecting ring surface has a plurality of clamping bushings arranged in a ring array, and the plurality of clamping bushings are straight column type.

[0016] Preferably, it also includes an upper tray, which is installed on the top of the upper connecting ring. The upper tray has a set of arc-shaped grooves on both sides of its top, with two arc-shaped grooves in each set. Multiple rectangular components are movably installed in one set of arc-shaped grooves to guide the wiring during the wiring process.

[0017] Preferably, the rectangular component is a copper wire guide block, which is concave, and the wire passes through the concave copper wire guide block.

[0018] Preferably, a groove is provided at one end of the inner wall of the upper connecting ring, and a stator limiting buckle is installed inside the groove. The stator limiting buckle is used to fix and limit the stator during the winding process.

[0019] Preferably, a slot is provided at the top edge of the upper connecting ring, and a support block is installed inside the slot. The top of the support block extends out of the slot to support and limit the cable reel.

[0020] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0021] 1. This utility model improves the accuracy and efficiency of stator winding in a round wire motor, while reducing damage to the insulation layer of the round wire, so as to meet the requirements of new energy vehicles for high performance and large-scale production of motors.

[0022] 2. This utility model improves the product qualification rate.

[0023] 3. This utility model improves production efficiency.

[0024] 4. This utility model improves the uniformity of products and the consistency of repeated positioning.

[0025] 5. This utility model optimizes durability and ease of maintenance for long-term use. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of this utility model.

[0027] In the diagram: 1. Product receiving base; 2. Middle connecting ring; 3. Upper connecting ring; 4. Upper tray; 5. Stator limit buckle; 6. Support block; 7. Arc groove; 8. Copper wire guide block; 9. Fixture bushing; 10. Slot; 11. Groove body. Detailed Implementation

[0028] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0029] Example 1: A tooling for producing stator windings for a new energy round wire motor, see [link / reference] Figure 1 Including positioning devices,

[0030] The positioning device includes a product receiving base 1, a central connecting ring 2 installed on the top of the product receiving base 1, and an upper connecting ring 3 fixed to the top of the central connecting ring 2. The product receiving base 1 is ring-shaped and is used to stably support the entire tooling. The central connecting ring 2 is used to connect and support the upper structure. The upper connecting ring 3 is connected to the central connecting ring 2 to form a stable frame structure for precise installation of the stator to be embedded.

[0031] For details, see Figure 1The upper connecting ring 3 has multiple clamp bushings 9 arranged in a ring array on its surface, and the multiple clamp bushings 9 are straight column type.

[0032] Further, see Figure 1 It also includes an upper tray 4, which is installed on the top of the upper connecting ring 3. A set of arc-shaped grooves 7 are provided on both sides of the top of the upper tray 4. There are two arc-shaped grooves 7 in each set. Multiple rectangular components are movably installed in one set of arc-shaped grooves 7 to guide the wiring during the wiring process.

[0033] It is worth noting that, see Figure 1 The rectangular component is the copper wire guide block 8, which is concave, and the wire passes through the concave copper wire guide block 8.

[0034] It is worth noting that, see Figure 1 The upper connecting ring 3 has a groove 11 on one end of its inner wall. A stator limiting buckle 5 is installed inside the groove 11. The stator limiting buckle 5 is used to fix and limit the stator during the winding process.

[0035] It is worth mentioning that, see Figure 1 A slot 10 is provided at the top edge of the upper connecting ring 3. A support block 6 is installed inside the slot 10. The top of the support block 6 extends out of the slot 10 to support and limit the cable tray.

[0036] When using a tooling for manufacturing stator windings for a new energy round wire motor:

[0037] 1. Preparation

[0038] Check whether all parts of the tooling are intact, including the wear of the winding die, the accuracy of the positioning device, the wear of the wire feeding wheel of the wire feeding mechanism, and the operating status of the power system of the pressing mechanism.

[0039] Install the stator to be embedded onto the positioning device, ensuring that the stator and the positioning block fit tightly together and that the positioning shaft is installed accurately.

[0040] 2. Embedding operation

[0041] Adjust parameters such as tension of the wire feeding mechanism, pressing force and pressing speed of the pressing mechanism according to the specifications of the round wire and the requirements of the stator slot.

[0042] Start the wire feeding and pressing mechanisms to begin the wire insertion operation. During the insertion process, the operator must closely observe the insertion to ensure that the round wire is smoothly inserted into the stator slot. If the round wire gets stuck or there are other abnormalities, the operation should be stopped immediately and adjustments made.

[0043] 3. Complete the inspection

[0044] After the wire insertion is completed, a preliminary inspection of the stator is performed to check whether the round wires are fully embedded in the stator slots and whether the arrangement is neat. Use measuring tools to check the positional accuracy of the round wires within the slots; for example, use calipers to measure the distance between the round wires and the stator slot wall, and the deviation should be within ±0.2mm. Also check for any damage to the insulation layer of the round wires.

[0045] In addition, all components designed in this utility model are general standard parts or components known to those skilled in the art. Their structure and principle can be learned by those skilled in the art through technical manuals or conventional experimental methods. Those skilled in the art can fully implement them, so there is no need to elaborate. The content protected by this utility model does not involve improvements to the internal structure and method.

[0046] The embodiments disclosed herein are preferred embodiments, but are not limited thereto. Those skilled in the art can readily grasp the spirit of this utility model based on the above embodiments and make different extensions and variations. However, as long as they do not depart from the spirit of this utility model, they are all within the protection scope of this utility model.

Claims

1. A tooling for producing stator windings for a new energy round wire motor, comprising a positioning device, characterized in that, The positioning device includes a product receiving base (1), a central connecting ring (2) installed on the top of the product receiving base (1), and an upper connecting ring (3) fixed to the top of the central connecting ring (2). The product receiving base (1) is ring-shaped and is used to stably support the entire tooling. The middle connecting ring (2) is used to connect and support the upper structure. The upper connecting ring (3) is connected to the middle connecting ring (2) to form a stable frame structure for precise installation of the stator to be embedded.

2. The stator winding production tooling for new energy round wire motors as described in claim 1, characterized in that, The upper connecting ring (3) has a ring array of multiple clamp bushings (9) distributed on its surface, and the multiple clamp bushings (9) are straight columns.

3. The stator winding production tooling for new energy round wire motors as described in claim 1, characterized in that, It also includes an upper tray (4), which is installed on the top of the upper connecting ring (3). The upper tray (4) has a set of arc grooves (7) on both sides of the top. There are two arc grooves (7) in each set. Multiple rectangular components are movably installed in one set of arc grooves (7) to guide the wiring during the wiring process.

4. The stator winding production tooling for new energy round wire motors as described in claim 3, characterized in that, The rectangular component is a copper wire guide block (8), which is concave, and the wire passes through the concave copper wire guide block (8).

5. The stator winding production tooling for new energy round wire motors as described in claim 1, characterized in that, The upper connecting ring (3) has a groove (11) on one end of its inner wall. A stator limiting buckle (5) is installed inside the groove (11). The stator limiting buckle (5) is used to fix and limit the stator during the winding process.

6. The stator winding production tooling for new energy round wire motors as described in claim 1, characterized in that, A slot (10) is provided at the top edge of the upper connecting ring (3). A support block (6) is installed inside the slot (10). The top of the support block (6) extends out of the slot (10) to support and limit the cable tray.

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