New energy flat wire motor stator flaring production tool

Abstract

The utility model relates to a new energy flat wire motor stator flaring production tool which comprises an upper pipe expanding tool and a lower pipe expanding tool, the upper pipe expanding tool comprises an upper pipe expanding deflector rod fixing plate and a first product bearing platform installed on the top of the upper pipe expanding deflector rod fixing plate, and the lower pipe expanding tool comprises a second product bearing platform installed on the top of the lower pipe expanding deflector rod fixing plate. The upper pipe expanding tool comprises an upper pipe expanding deflector rod fixing plate, a first product bearing platform connected with the top of the upper pipe expanding deflector rod fixing plate, and an upper pipe expanding deflector rod located between the upper pipe expanding deflector rod fixing plate and the first product bearing platform, and the lower pipe expanding tool comprises a lower pipe expanding deflector rod fixing plate, a second product bearing platform connected with the top of the lower pipe expanding deflector rod fixing plate and a lower pipe expanding deflector rod located between the lower pipe expanding deflector rod fixing plate and the second product bearing platform; precise flaring operation of the flat wire motor stator is achieved, it is ensured that the flaring size meets the requirement, meanwhile, production efficiency is improved, the rejection rate is reduced, multi-angle movement in the complex radial direction is achieved through mutual conversion and utilization between mechanical structures in the process, JIG correction in the actual use process is matched, and quality and production efficiency are effectively improved.

Description

Technical Field

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

[0002] With increasing global focus on environmental protection and energy sustainability, the new energy vehicle market is developing rapidly. As one of the core components of new energy vehicles, the performance of flat-wire motors directly affects the vehicle's power, range, and energy efficiency. For example, flat-wire motors have higher power density than traditional round-wire motors, enabling them to output greater power within the same volume. This is crucial for improving the acceleration performance of new energy vehicles and reducing battery consumption.

[0003] In the fiercely competitive new energy vehicle market, automakers are constantly pursuing higher performance and more reliable motor products. This prompts motor manufacturers to continuously improve their production processes and enhance the manufacturing quality of flat wire motor stators. The stator flaring process, as a crucial step in stator manufacturing, directly impacts stator quality and production efficiency through the sophistication and reliability of its tooling technology, thereby affecting the overall competitiveness of the motor product in the market.

[0004] The stator windings of a flat-wire motor use flat-shaped conductors. This structure allows for a more compact spatial layout of the stator windings, but it also presents challenges in the manufacturing process. The ends of the stator need to be flared to facilitate the insertion and fixation of the windings. Compared to traditional round-wire motor stators, the flaring precision requirements for flat-wire motor stators are higher because the shape and arrangement of the flat wires are more sensitive to the electromagnetic performance of the motor.

[0005] In the manufacturing process of flat wire motor stators, traditional flaring techniques and tooling are insufficient to meet the requirements of high precision and high efficiency. For example:

[0006] 1. Dimensional accuracy

[0007] The dimensional accuracy requirements for the stator flare are extremely high. If the tooling cannot guarantee such accuracy, it will lead to poor fit between the windings and the stator slots, affecting the motor's performance, such as reducing motor efficiency and increasing motor vibration and noise.

[0008] 2. Shape accuracy

[0009] The flaring shape must closely match the design requirements. An uneven flaring shape may cause uneven distribution of the flat wires in the stator slots, thereby affecting the magnetic field distribution and reducing the electromagnetic performance of the motor. This requires the tooling to apply uniform force to all parts of the stator during the flaring process to avoid excessive local deformation.

[0010] 3. Physical damage

[0011] The stator windings of flat-wire motors are typically composed of multiple strands of fine flat wire, which are susceptible to physical damage such as scratches and deformation during the flaring process. Even minor scratches, if their depth exceeds a certain value, can damage the insulation layer of the flat wire, leading to short-circuit faults and seriously affecting the reliability and safety of the motor.

[0012] 4. Flaring speed

[0013] To meet the demands of large-scale production, the flaring speed of the tooling needs to be optimized. If the flaring speed is too slow, it will reduce production efficiency and increase production costs; however, if the flaring speed is too fast, it may lead to difficulty in controlling accuracy and also increase the risk of winding damage.

[0014] 5. Reliable automation

[0015] In modern manufacturing, tooling needs to be easily integrated with automated production lines. This includes integration with automated material handling equipment, inspection equipment, and so on. If tooling cannot be well integrated with automation, it will increase the need for manual intervention, further reduce production efficiency, and may introduce human error.

[0016] 6. Durability

[0017] Due to the large-scale production of new energy flat wire motors, tooling needs to be used frequently. Components of the tooling, such as flaring dies and positioning devices, need to have high durability to reduce the frequency of component replacement. For example, if the flaring die is prone to wear, it will lead to a decrease in flaring accuracy, requiring frequent replacement, which will increase production downtime and costs.

[0018] 7. Ease of maintenance

[0019] Tooling should be easy to maintain. Tooling with complex structures and inconvenient maintenance will increase maintenance costs and time. For example, power system maintenance should be simple and easy, and components should be easy to disassemble and replace.

[0020] Therefore, we propose a new type of stator flaring production tooling for new energy flat wire motors to achieve precise flaring operation of the stator, ensuring that the flaring size meets the design requirements, while improving production efficiency and reducing scrap rate. The process mainly utilizes the mutual conversion between mechanical structures to achieve complex radial multi-angle movement, combined with the correction jig in actual use, effectively improving quality stability and production efficiency. Utility Model Content

[0021] The purpose of this invention is to overcome the shortcomings of existing technologies and adapt to practical needs by providing a new energy flat wire motor stator flaring production tooling. This addresses the current limitations of traditional flaring processes and tooling in meeting the requirements of high precision and efficiency in flat wire motor stator manufacturing. For example, traditional tooling may not be able to accurately control the size and shape of the flaring, easily leading to poor fit between the flat wire winding and the stator slot. Furthermore, the fragility of flat wire requires the tooling to avoid damage during the flaring process, necessitating new tooling technology to achieve precise force control and positioning. Currently, existing flat wire motor stator flaring production tooling generally suffers from high manufacturing costs, low production efficiency, and a relatively high scrap rate.

[0022] To achieve the purpose of this utility model, the technical solution adopted by this utility model is as follows: design a new energy flat wire motor stator flaring production tooling, including an upper flaring tooling and a lower flaring tooling. The upper flaring tooling includes an upper flaring lever fixing plate, a first product receiving platform installed on the top of the upper flaring lever fixing plate, and an upper flaring lever located between the upper flaring lever fixing plate and the first product receiving platform.

[0023] The lower expansion tube tooling includes a lower expansion tube lever fixing plate, a second product receiving platform connected to the top of the lower expansion tube lever fixing plate, and a lower expansion tube lever located between the lower expansion tube lever fixing plate and the second product receiving platform.

[0024] Both the first and second product receiving platforms are circular, with an opening at one end of the arc-shaped surface. An upper expansion tube lever and a lower expansion tube lever pass through the opening. One end of each lever extends out of the opening, while the other end extends between the upper expansion tube lever fixing plate and the first product receiving platform, and between the lower expansion tube lever fixing plate and the second product receiving platform. Each lever is integrally formed with a rotatable movable ring inside it. The surface of the movable ring is provided with multiple movable pins, which enable the flaring operation of the upper and lower parts of the stator through radial rotation.

[0025] Preferably, the bottom of the movable ring between the upper expansion tube lever fixing plate and the first product receiving platform has multiple upper movable pins arranged in a ring shape, which can drive the multiple upper movable pins to rotate.

[0026] Preferably, the bottom of the movable ring between the lower expansion tube lever fixing plate and the second product receiving platform has multiple lower moving pins distributed in a ring shape, which can drive the multiple lower moving pins to rotate.

[0027] Preferably, both the first product receiving platform and the second product receiving platform have circular holes on their surfaces, and multiple slots are arranged in a ring array inside the circular holes. The multiple slots engage with the locking blocks on the surface of the straightening JIG, which are used to place the straightening JIG into the upper and lower tube expanding fixtures to straighten the relative positions of the upper and lower tube expanding fixtures.

[0028] Preferably, the number of upper moving pins in the upper tube expansion fixture and the number of lower moving pins in the lower tube expansion fixture are both 96.

[0029] Preferably, the upper moving PIN and the lower moving PIN cover the flat wires that need to be expanded at the top and bottom of the stator.

[0030] Preferably, an equipment mounting base plate is installed at the bottom of the lower expansion tube lever fixing plate.

[0031] Preferably, the upper expansion lever is used to drive multiple upper moving pins to move radially, so as to realize the expansion operation of the flat wire at the top of the stator.

[0032] Preferably, the lower expansion lever is used to drive multiple lower moving pins to move radially, thereby realizing the expansion operation of the flat wire at the lower part of the stator.

[0033] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0034] 1. This utility model realizes the precise flaring operation of the stator of the flat wire motor, ensuring that the flaring size meets the design requirements, while improving production efficiency and reducing scrap rate. The process mainly utilizes the mutual conversion between mechanical structures to achieve complex radial multi-angle movement, combined with the correction jig in actual use, effectively improving quality stability and production efficiency.

[0035] 2. This utility model improves the product qualification rate.

[0036] 3. This utility model improves production efficiency.

[0037] 4. This utility model improves the uniformity of products and the consistency of repeated positioning.

[0038] 5. This utility model optimizes durability and ease of maintenance for long-term use. Attached Figure Description

[0039] Figure 1 This is a schematic diagram of the lower expansion tube tooling structure of this utility model;

[0040] Figure 2 This is a schematic diagram of the upward expansion pipe tooling structure of this utility model.

[0041] In the diagram: 1. Equipment mounting base plate; 2. Second product receiving platform; 3. Lower moving pin; 4. Lower tube expansion lever; 5. Upper tube expansion lever fixing plate; 6. Upper moving pin; 7. Upper tube expansion lever; 8. Lower tube expansion lever fixing plate; 9. First product receiving platform; 10. Round hole; 11. Tank. Detailed Implementation

[0042] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0043] Example 1: A tooling for producing a flared stator for a new energy flat wire motor, see [link / reference]. Figures 1 to 2 The system includes an upper expansion tooling and a lower expansion tooling. The upper expansion tooling includes an upper expansion rod fixing plate 5, a first product receiving platform 9 installed on the top of the upper expansion rod fixing plate 5, and an upper expansion rod 7 located between the upper expansion rod fixing plate 5 and the first product receiving platform 9. The lower expansion tooling includes a lower expansion rod fixing plate 8, a second product receiving platform 2 connected to the top of the lower expansion rod fixing plate 8, and a lower expansion rod 4 located between the lower expansion rod fixing plate 8 and the second product receiving platform 2. The first product receiving platform 9 and the second product receiving platform 9 are also included. The receiving platform 2 is circular, and an opening is opened at one end of the circular arc surface. The upper expansion tube lever 7 and the lower expansion tube lever 4 pass through the opening. One end of the upper expansion tube lever 7 and the lower expansion tube lever 4 extends out of the opening, and the other end extends into the space between the upper expansion tube lever fixing plate 5 and the first product receiving platform 9, and between the lower expansion tube lever fixing plate 8 and the second product receiving platform 2. They are integrally formed with the internal rotatable moving rings. The surface of the moving rings is provided with multiple moving pins, and the radial rotation realizes the expansion operation of the upper and lower parts of the stator.

[0044] For details, see Figure 2 The bottom of the movable ring between the upper expansion tube lever fixing plate 5 and the first product receiving platform 9 has multiple upper movable pins 6 arranged in a ring shape, which can drive the multiple upper movable pins 6 to rotate.

[0045] For more details, see Figure 2 The bottom of the moving ring between the lower expansion tube lever fixing plate 8 and the second product receiving platform 2 has multiple lower moving pins 3 arranged in a ring shape, which can drive the multiple lower moving pins 3 to rotate.

[0046] Further, see Figure 1 Both the first product receiving platform 9 and the second product receiving platform 2 have circular holes 10 on their surfaces, and multiple slots 11 are arranged in a ring array inside the circular holes 10. The multiple slots 11 engage with the clips on the surface of the straightening JIG, which are used to place the straightening JIG into the upper and lower tube expanding fixtures to straighten the relative position of the upper and lower tube expanding fixtures.

[0047] For the next step, see Figure 1 The number of upper moving pins 6 in the upper tube expansion fixture and the number of lower moving pins 3 in the lower tube expansion fixture are both 96.

[0048] It is worth noting that, see Figure 1 and Figure 2 The upper moving PIN 6 and the lower moving PIN 3 cover the flat wires that need to be expanded at the top and bottom of the stator.

[0049] It is worth noting that, see Figure 1 and Figure 2 The bottom of the lower expansion tube lever fixing plate 8 is equipped with an equipment mounting base plate 1.

[0050] It is worth noting that, see Figure 2 The upper expansion lever 7 is used to drive multiple upper moving pins 6 to move radially in order to achieve the flaring operation of the top flat wire of the stator.

[0051] It is worth mentioning that, see Figure 1 The lower expansion lever 4 is used to drive multiple lower moving pins 3 to move radially, thereby realizing the expansion operation of the flat wire at the bottom of the stator.

[0052] When using a tooling for flaring the stator of a new energy flat wire motor:

[0053] 1. Preparation

[0054] Check the condition of each component of the tooling, including the wear of the flaring mold (96 pins on each side), the accuracy of the positioning device, and the operating status of the power system. Place the upper and lower tube flaring tooling straightening jig into the upper and lower tooling and straighten the relative positions of the upper and lower tube flaring tooling. After the straightening is completed, close the door and start the formal production.

[0055] The conveyor line discharges the stator from the previous section and transfers it to this section via a transfer tray. The stator is then picked up by a cylinder gripper in conjunction with a moving servo motor and put into the flaring production tooling.

[0056] 2. Flaring operation

[0057] Once the sensor detects that the stator has been placed in the correct position, the power system is activated, and the flaring operation is performed according to the set parameters (such as flaring force and speed). The upper and lower cylinders respectively push the upper flaring lever 7 and the lower flaring lever 4 to move, which in turn drive the upper moving PIN pin 6 and the lower moving PIN pin 3 to move radially, expanding all the PIN pins towards the center of the product.

[0058] 3. Complete the inspection

[0059] After flaring, the lever rotates in the opposite direction, and the PIN moves radially back, completing the product discharge. The product continues to flow downwards, and on-site personnel periodically use measuring tools (such as calipers and micrometers) to check whether the flared dimensions meet the requirements. If they are not up to standard, the cause must be analyzed, and the tooling adjusted or the stator reworked.

[0060] 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.

[0061] 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 new energy flat wire motor stator flaring production tooling, comprising an upper tube flaring tooling and a lower tube flaring tooling, characterized in that, The upper tube expanding tooling includes an upper tube expanding lever fixing plate (5), a first product receiving platform (9) mounted on the top of the upper tube expanding lever fixing plate (5), and an upper tube expanding lever (7) located between the upper tube expanding lever fixing plate (5) and the first product receiving platform (9); The lower tube expanding tooling includes a lower tube expanding lever fixing plate (8), a second product receiving platform (2) connected to the top of the lower tube expanding lever fixing plate (8), and a lower tube expanding lever (4) located between the lower tube expanding lever fixing plate (8) and the second product receiving platform (2); The first product receiving platform (9) and the second product receiving platform (2) are both circular, and one end of the arc surface of the circular shape is provided with an opening, and the upper tube expanding lever (7) and the lower tube expanding lever (4) penetrate through the opening, one end of the upper tube expanding lever (7) and the lower tube expanding lever (4) extends out of the opening, and the other end extends into the space between the upper tube expanding lever fixing plate (5) and the first product receiving platform (9) and the space between the lower tube expanding lever fixing plate (8) and the second product receiving platform (2), and is integrally formed with the internally rotatable moving ring, and the surface of the moving ring is provided with a plurality of moving PIN needles, and the radial rotation realizes the flaring operation of the upper part and the lower part of the stator.

2. The new energy flat wire motor stator flaring production tool of claim 1, wherein, A plurality of upper moving PIN needles (6) are annularly distributed at the bottom of the moving ring between the upper tube expanding lever fixing plate (5) and the first product receiving platform (9), which can drive the plurality of upper moving PIN needles (6) to rotate.

3. The new energy flat wire motor stator flaring production tool of claim 1, wherein, A plurality of lower moving PIN needles (3) are annularly distributed at the bottom of the moving ring between the lower tube expanding lever fixing plate (8) and the second product receiving platform (2), which can drive the plurality of lower moving PIN needles (3) to rotate.

4. The new energy flat wire motor stator flaring production tool of claim 1, wherein, A plurality of grooves (11) are annularly arranged in the circular hole (10) on the surface of the first product receiving platform (9) and the second product receiving platform (2), and the plurality of grooves (11) are engaged with the clamping blocks on the surface of the correcting JIG, which is used to put the correcting JIG into the upper tube expanding tooling and the lower tube expanding tooling, and correct the relative position of the upper tube expanding tooling and the lower tube expanding tooling.

5. The new energy flat wire motor stator flaring production tool of claim 1, wherein, The number of the upper moving PIN needles (6) in the upper tube expanding tooling and the number of the lower moving PIN needles (3) in the lower tube expanding tooling are both 96.

6. The new energy flat wire motor stator flaring production tool of claim 2, wherein, The upper moving PIN needles (6) and the lower moving PIN needles (3) cover the flat wires on the top and the bottom of the stator which need to be expanded.

7. The new energy flat wire motor stator flaring production tool of claim 1, wherein, The lower tube expanding lever fixing plate (8) is mounted with an equipment mounting bottom plate (1).

8. The new energy flat wire motor stator flaring production tool of claim 1, wherein, The upper tube expanding lever (7) is used to drive the plurality of upper moving PIN needles (6) to move radially, so as to realize the flaring operation of the flat wires on the top of the stator.

9. The new energy flat wire motor stator flaring production tool of claim 1, wherein, The lower tube expanding lever (4) is used to drive the plurality of lower moving PIN needles (3) to move radially, so as to realize the flaring operation of the flat wires on the bottom of the stator.

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