Flat wire stator welding clamp
By designing the jaw structure of the flat wire stator welding fixture, precise positioning and clamping of the exposed straight section of the copper wire can be achieved, solving the problem of poor positioning effect in the existing fixture and improving welding quality and versatility.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- ZHEJIANG ZEEKR INTELLIGENT TECH CO LTD
- Filing Date
- 2025-06-05
- Publication Date
- 2026-05-08
AI Technical Summary
In the existing flat wire stator welding process, the positioning effect of the exposed straight section of the copper wire is poor, which easily leads to gaps and misalignments, affecting the welding quality and welding yield. In addition, the positioning tooling is not versatile enough.
A flat wire stator welding fixture is designed, including a first jaw and a second jaw. By moving the jaws and positioning the protruding structure, the exposed straight segments of the copper wire are accurately positioned and clamped, ensuring that there are no gaps in the radial direction for each group of exposed straight segments of the copper wire, thereby improving the welding quality and welding yield.
It improves the clamping and positioning accuracy of exposed straight sections of copper wire, ensures gap-free welding, enhances welding quality and yield, avoids burning of unstripped enameled wire, and enhances the versatility of welding fixtures.
Smart Images
Figure CN224209388U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of vehicle parts processing technology, and more specifically, to a flat wire stator welding fixture. Background Technology
[0002] Compared to ordinary stators, the copper wires in the stator windings of a flat wire stator are not round, but have rectangular or flat cross-sections. This flat wire design, compared to traditional round copper wires, helps to arrange the wires more efficiently in the slots of the stator core. In other words, the flat wire allows the stator windings to arrange a larger number of coils in a more compact space, which is very important for improving the power density and performance of the motor.
[0003] During the assembly of the flat wire stator, multiple rectangular copper wires are first inserted into slots at different indexing positions of the stator core. Then, according to the requirements of the three-phase motor, the portions of the copper wires extending beyond the slots at different indexing positions are flared and twisted (twisted circumferentially along the stator core). After flaring and twisting, the portion of each copper wire extending beyond the slot deviates from its corresponding slot. At this point, the portion of each copper wire extending beyond the slot includes both the exposed straight section and the bent section. Furthermore, after flaring and twisting, the exposed straight sections of two copper wires in different slots are placed side-by-side and close together. Ultimately, this results in exposed straight sections of copper wire at different indexing positions on the stator core, with multiple sets of exposed straight sections at each indexing position of the stator core.
[0004] After flaring and twisting, the enameled wire at the outer end of each group of exposed straight copper wires needs to be stripped (or stripped before the copper wire is inserted into the slot). Then, each group of exposed straight copper wires is welded together to form a single unit. To ensure the reliability of the weld, each group of exposed straight copper wires needs to be positioned before welding.
[0005] Currently, the most common welding positioning method used in the industry is a positioning fixture. This fixture is disc-shaped with multiple positioning holes, each for inserting a set of exposed copper wire segments to position them. However, to facilitate insertion, the positioning holes are typically larger than the total size of the exposed copper wire segments. This results in poor positioning of each set, leading to gaps and misalignments between them. Ultimately, this affects welding quality, yield, and pull-out force. Especially if gaps or openings exist between sets, the remaining enameled wire on the exposed segments can be burned during welding. Furthermore, this type of positioning fixture is designed for specific flat wire stators, lacking versatility and generally only compatible with one type of flat wire stator. Utility Model Content
[0006] This utility model aims to solve at least one of the above-mentioned technical problems.
[0007] To address the aforementioned problems, this utility model provides a flat wire stator welding fixture, comprising a first clamp and a second clamp. The first clamp and the second clamp are sequentially arranged along a second direction and are movably connected to each other along a first direction. The first clamp and the second clamp are respectively provided with a through-hole for inserting an exposed straight segment of copper wire from the flat wire stator. The through-hole's penetration direction is parallel to the second direction, and the through-hole's extension direction is parallel to the first direction. The first clamp and the second clamp are used to move relative to each other to jointly clamp the exposed straight segment of copper wire passing through the through-hole. The first direction is perpendicular to the second direction.
[0008] The flat wire stator has multiple sets of exposed copper wire straight segments at each indexing position, and these multiple sets of exposed copper wire straight segments at each indexing position are arranged radially along the stator core. The first and second jaws of the flat wire stator welding fixture can each be provided with a through-hole. In practical applications, a certain indexing position of the flat wire stator can be aligned with the extension direction of the through-hole, that is, the extension direction of the through-hole of the flat wire stator welding fixture is consistent with the radial direction of a certain indexing position of the flat wire stator. This flat wire stator welding fixture can sequentially clamp and position multiple groups of exposed copper wire straight segments at the indexing position in the first direction, so that each group of exposed copper wire straight segments is clamped in the radial direction. After each group of exposed copper wire straight segments is clamped and positioned, it is then welded. Through this "clamping one group after another" and "welding one group after another", the clamping and positioning accuracy of each group of exposed copper wire straight segments in the radial direction can be improved, ensuring that there is no gap in the first direction when welding each group of exposed copper wire straight segments, thereby improving welding quality, welding yield and weld pull-out force. Moreover, the unstripped enameled wire on the exposed copper wire straight segments will not be burned during welding.
[0009] Specifically, when it is necessary to clamp and position a certain group of exposed copper wire straight segments at the indexing position, for example, when it is necessary to clamp and position the innermost group of exposed copper wire straight segments at the indexing position, the opening of the second jaw can be fitted onto all the exposed copper wire straight segments at the indexing position, while the opening of the first jaw can be fitted onto the exposed copper wire straight segments at the indexing position excluding the innermost group; then the first jaw can be moved relative to the second jaw to achieve the clamping and positioning of the innermost group of exposed copper wire straight segments by the first jaw and the second jaw together, ensuring that when clamping and positioning a certain group of exposed copper wire straight segments, there will be no movement interference with the exposed copper wire straight segments of other groups.
[0010] Furthermore, both the first gripper and the second gripper include a first end extending from the same end along the first direction; the first end of the first gripper is used to move along the first direction toward the first end of the second gripper, so as to clamp and fix together with the first end of the second gripper a set of exposed straight segments of copper wire that only pass through the opening of the second gripper.
[0011] Furthermore, the second gripper has a positioning protrusion on its side facing the first gripper, and the positioning protrusion is located at the first end of the second gripper. When the first end of the first gripper moves relative to the second gripper to abut against the positioning protrusion, the first end of the first gripper and the first end of the second gripper together clamp and fix a set of exposed straight sections of copper wire that only pass through the opening of the second gripper.
[0012] Furthermore, the first end of the first gripper has a protruding first protrusion, which is inserted into the opening of the second gripper and is used to move along the opening of the second gripper.
[0013] Furthermore, the flat wire stator welding fixture also includes a main power telescopic component and a first power telescopic component. The main power telescopic component is driven to the second gripper, and the main power telescopic component is driven to the first gripper through the first power telescopic component. The telescopic directions of the main power telescopic component and the first power telescopic component are both parallel to the first direction.
[0014] Furthermore, the flat wire stator welding fixture also includes two third jaws and two second power telescopic members symmetrically arranged about the extension direction of the through-hole. The two second power telescopic members are respectively fixed relative to the second jaws, and the two second power telescopic members are respectively driven connected to the third jaws on the corresponding side. The two second power telescopic members are used to drive the two third jaws to perform a clamping action in a third direction, so as to clamp at least a group of exposed straight segments of copper wire that only pass through the through-hole of the second jaws; wherein, the third direction is perpendicular to the first direction and the second direction respectively.
[0015] Furthermore, the first gripper is disposed on the side of the second gripper away from the stator core of the flat wire stator; the third gripper includes a clamping part and a connecting part, the connecting part is located on the side of the first gripper away from the second gripper, the connecting part is connected to the second power telescopic member, the second end of the clamping part is connected to the connecting part, the first end of the clamping part gradually tilts towards the first end of the second gripper and contacts the side of the first end of the second gripper facing the first gripper.
[0016] Furthermore, the first end of the first gripper is provided with a clearance ramp for avoiding the gripping portion; and / or, along the third direction, the size of the gripping portion is smaller than the size of the connecting portion.
[0017] Furthermore, the first end of the clamping part is provided with a second protrusion, the protrusion direction of the second protrusion is parallel to the third direction, and the second protrusion is used to insert between two adjacent sets of exposed straight segments of copper wires in the extension direction of the through-hole; the second protrusions of the two clamping parts are used to abut against each other to restrict the clamping movement of the two third jaws.
[0018] Furthermore, a rib protrudes from the side of the clamping part away from the second gripper, and the rib extends from the second end of the clamping part toward its first end. Attached Figure Description
[0019] Figure 1 This is a schematic diagram of the flat wire stator welding fixture of this utility model. Figure 1 ;
[0020] Figure 2 for Figure 1 Enlarged view of point A in the middle;
[0021] Figure 3 for Figure 1 Top view;
[0022] Figure 4 for Figure 3 Enlarged view of point B in the middle;
[0023] Figure 5 This is a schematic diagram of the cooperation structure between the first and second grippers and a set of exposed straight sections of copper wire in an embodiment of the present invention.
[0024] Figure 6 for Figure 5 Side view;
[0025] Figure 7 This is a schematic diagram of the flat wire stator welding fixture of this utility model. Figure 2 ;
[0026] Figure 8 for Figure 7 Enlarged view of point C in the middle;
[0027] Figure 9 for Figure 7 Top view;
[0028] Figure 10 for Figure 9 Enlarged view of point D in the middle;
[0029] Figure 11This is a schematic diagram of the cooperation structure between the third gripper, the first gripper, and the second gripper and a set of exposed straight sections of copper wire in an embodiment of this utility model.
[0030] Explanation of reference numerals in the attached figures:
[0031] 1. First gripper; 11. First protrusion; 12. Protrusion; 13. Avoidance ramp; 2. Second gripper; 21. Positioning protrusion; 3. Through opening; 41. Stator core; 42. Exposed straight section of copper wire; 5. Main power telescopic component; 6. Intermediate connecting rod; 7. Third gripper; 71. Clamping part; 711. Second protrusion; 712. Rib plate; 72. Connecting part; 8. Second power telescopic component. Detailed Implementation
[0032] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings.
[0033] In the description of this utility model, it should be understood that the terms "upper", "lower", "left", "right", "front", "rear", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.
[0034] It should also be noted that the Z-axis, Y-axis and X-axis in the accompanying drawings are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.
[0035] See Figure 1-5 A flat wire stator welding fixture according to an embodiment of the present invention includes a first clamp 1 and a second clamp 2. The first clamp 1 and the second clamp 2 are arranged sequentially along a second direction and are movably connected to each other along a first direction. The first clamp 1 and the second clamp 2 are respectively provided with a through-hole 3 for inserting the exposed straight section 42 of the copper wire of the flat wire stator. The through-hole 3 is parallel to the second direction and the extension direction of the through-hole 3 is parallel to the first direction. The first clamp 1 is used to move relative to the second clamp 2 so as to clamp the exposed straight section 42 of the copper wire passing through the through-hole 3 together with the second clamp 2. The first direction is perpendicular to the second direction.
[0036] In related technologies, flat wire stators have multiple sets of exposed copper wire straight segments 42 at each indexing position, and the multiple sets of exposed copper wire straight segments 42 at each indexing position are arranged radially along the stator core. In this embodiment, the first jaw 1 and the second jaw 2 of the flat wire stator welding fixture can each be provided with a through-hole 3. In actual application, a certain indexing position of the flat wire stator can be aligned with the extension direction of the through-hole 3, that is, the extension direction of the through-hole 3 of the flat wire stator welding fixture is consistent with the radial direction of a certain indexing position of the flat wire stator. The flat wire stator welding fixture can sequentially clamp and position multiple groups of exposed copper wire straight segments 42 at the indexing position in the first direction, so that each group of exposed copper wire straight segments 42 is clamped in the radial direction. After each group of exposed copper wire straight segments 42 is clamped and positioned, it is then welded. Through this "clamping one group after another" and "welding one group after another", the clamping and positioning accuracy of each group of exposed copper wire straight segments 42 in the radial direction can be improved, ensuring that there will be no gap in the radial direction of the stator core when each group of exposed copper wire straight segments 42 is welded, thereby improving the welding quality, welding yield and weld pull-out force. Moreover, the unstripped enameled wire on the exposed copper wire straight segments 42 will not be burned during welding.
[0037] Specifically, when it is necessary to clamp and position a certain group of exposed copper wire straight segments 42 at the indexing position, for example, when it is necessary to clamp and position the innermost group of exposed copper wire straight segments 42 at the indexing position, the through-hole 3 of the second jaw 2 can be fitted onto all exposed copper wire straight segments 42 at the indexing position, and the through-hole 3 of the first jaw 1 can be fitted onto the exposed copper wire straight segments 42 at the indexing position excluding the innermost group; then the first jaw 1 can be moved relative to the second jaw 2 so that the first jaw 1 and the second jaw 2 can jointly clamp and position the innermost group of exposed copper wire straight segments 42, ensuring that when clamping and positioning a certain group of exposed copper wire straight segments 42, there will be no movement interference with other groups of exposed copper wire straight segments 42.
[0038] For ease of understanding, such as Figure 1-4 as well as Figure 7-10 As shown, the following text uses the first direction as the X-axis direction and the second direction as the Z-axis direction as examples for illustration; the example is that each indexing position of the stator core 41 has four sets of exposed copper wire straight segments 42, which are called the first set of exposed copper wire straight segments 42, the second set of exposed copper wire straight segments 42, the third set of exposed copper wire straight segments 42 and the fourth set of exposed copper wire straight segments 42 from the inside to the outside.
[0039] For example, when it is necessary to clamp and position the first group of exposed copper wire straight segments 42 at a certain indexing position, the opening 3 of the second jaw 2 can be placed on the fourth group of exposed copper wire straight segments 42 at the indexing position, and the opening 3 of the first jaw 1 can be placed on the second, third and fourth groups of exposed copper wire straight segments 42 at the indexing position. Then, the first jaw 1 can be moved relative to the second jaw 2 so that when the first jaw 1 and the second jaw 2 clamp and position the first group of exposed copper wire straight segments 42 at the indexing position, there will be no movement interference with the exposed copper wire straight segments 42 of other groups.
[0040] When it is necessary to clamp and position the exposed straight section 42 of the second group of copper wires at a certain indexing position, the through-hole 3 of the second jaw 2 can be fitted onto the exposed straight sections 42 of the second, third, and fourth groups of copper wires at the indexing position, while the through-hole 3 of the first jaw 1 can be fitted onto the exposed straight sections 42 of the third and fourth groups of copper wires at the indexing position; then the first jaw 1 can be moved relative to the second jaw 2 to achieve clamping and positioning of the exposed straight section 42 of the second group of copper wires by the first jaw 1 and the second jaw 2.
[0041] When it is necessary to clamp and position the exposed straight section 42 of the third group of copper wires at a certain indexing position, the through-hole 3 of the second jaw 2 can be fitted onto the exposed straight section 42 of the third and fourth groups of copper wires at the indexing position, and the through-hole 3 of the first jaw 1 can be fitted onto the exposed straight section 42 of the fourth group of copper wires at the indexing position; then the first jaw 1 can be moved relative to the second jaw 2 to achieve the clamping and positioning of the exposed straight section 42 of the third group of copper wires by the first jaw 1 and the second jaw 2.
[0042] like Figure 1-4 As shown, when it is necessary to clamp and position the exposed straight section 42 of the fourth group of copper wires at a certain indexing position, the through-hole 3 of the second jaw 2 can be fitted onto the exposed straight section 42 of the fourth group of copper wires at that indexing position, while the first jaw 1 is located on the side of the exposed straight section 42 of the fourth group of copper wires away from the central axis of the stator core 41; then the first jaw 1 can be moved relative to the second jaw 2 to achieve the clamping and positioning of the exposed straight section 42 of the fourth group of copper wires by the first jaw 1 and the second jaw 2.
[0043] It should be noted that the spacing between the exposed straight sections 42 of copper wires in adjacent groups will vary for different product models of flat wire stators. In this embodiment, since the first clamp 1 and the second clamp 2 can move relative to each other, each group of exposed straight sections 42 of copper wires can be clamped individually. This improves the versatility of the flat wire stator welding fixture for different product models of flat wire stators, such as Hair-pin models (hairpin type stators), I-pin models (I-type stators), and Umini-pin models (mini U-type stators).
[0044] In other embodiments, when it is necessary to clamp and position a group of exposed straight copper wire segments 42 at a certain indexing position, the openings 3 of the first jaw 1 and the second jaw 2 can be fitted onto the group of exposed straight copper wire segments 42, and then the first jaw 1 and the second jaw 2 can be driven to move relative to each other to clamp the group of exposed straight copper wire segments 42. Alternatively, the first jaw 1 and the second jaw 2 can each have multiple openings 3. In this case, when it is necessary to clamp multiple sets of exposed copper wire straight segments 42 at the indexing position, each set of exposed copper wire straight segments 42 at the indexing position can be inserted into the corresponding openings 3 of the first jaw 1 and the second jaw 2. That is, each opening 3 of the first jaw 1 and the second jaw 2 can be filled with a set of exposed copper wire straight segments 42. Then, the first jaw 1 can be moved relative to the second jaw 2, thereby simultaneously clamping and fixing multiple sets of exposed copper wire straight segments 42 at the indexing position in the first direction. For example, if each indexing position of the stator core 41 has four sets of exposed copper wire straight segments 42 (these four sets of exposed copper wire straight segments 42 are sequentially named from the inside out as the first set of exposed copper wire straight segments 42, the second set of exposed copper wire straight segments 42, the third set of exposed copper wire straight segments 42, and the fourth set of exposed copper wire straight segments 42), then... (Section 42) Then, the first clamp 1 and the second clamp 2 each have four through-holes 3, and these through-holes 3 are arranged sequentially along the first direction. The four through-holes 3 on the first clamp 1 and the second clamp 2 are the first through-hole, the second through-hole, the third through-hole and the fourth through-hole, respectively. When it is necessary to clamp the four sets of exposed copper wire straight segments 42 at the indexing position, the first set of exposed copper wire straight segments 42 can be inserted into the first through-hole of the second clamp 2 and the first clamp 1, the second set of exposed copper wire straight segments 42 can be inserted into the second through-hole of the second clamp 2 and the first clamp 1, the third set of exposed copper wire straight segments 42 can be inserted into the third through-hole of the second clamp 2 and the first clamp 1, and the fourth set of exposed copper wire straight segments 42 can be inserted into the fourth through-hole of the second clamp 2 and the first clamp 1. Then, the first clamp 1 is moved relative to the second clamp 2, so that the clamping and fixing of the four sets of exposed copper wire straight segments 42 at the indexing position in the first direction can be completed simultaneously.
[0045] See Figure 1-5 Preferably, both the first gripper 1 and the second gripper 2 include a first end extending from the same end along the first direction; the first end of the first gripper 1 is used to move along the first direction toward the first end of the second gripper 2 so as to clamp and fix together with the first end of the second gripper 2 a group of exposed straight segments 42 of copper wires that only pass through the opening 3 of the second gripper 2.
[0046] In this embodiment, the first jaw 1 has a through-hole 3 and the second jaw 2 has a through-hole 3 respectively. As mentioned above, the flat wire stator welding fixture can sequentially clamp and position multiple sets of exposed copper wire straight segments 42 at the indexing position in the radial direction. After each set of exposed copper wire straight segments 42 is clamped and positioned, it is then welded. Through this "clamping one set after another" and "welding one set after another", the radial clamping and positioning accuracy of each set of exposed copper wire straight segments 42 can be improved, ensuring that there will be no gap in the radial direction of the stator core when welding each set of exposed copper wire straight segments 42, thereby improving the welding quality, welding yield and weld pull-out force. Moreover, the unstripped enameled wire on the exposed copper wire straight segments 42 will not be burned during welding.
[0047] For example, when it is necessary to clamp and position the first group of exposed copper wire straight segments 42 at a certain indexing position, the through-hole 3 of the second jaw 2 can be fitted onto the four groups of exposed copper wire straight segments 42 at the indexing position, while the through-hole 3 of the first jaw 1 can be fitted onto the second, third, and fourth groups of exposed copper wire straight segments 42 at the indexing position; then the first jaw 1 can be moved relative to the second jaw 2, so that the first end of the first jaw 1 and the first end of the second jaw 2 together clamp and fix the first group of exposed copper wire straight segments 42 that only pass through the through-hole 3 of the second jaw 2, without causing movement interference with the other groups of exposed copper wire straight segments 42.
[0048] See Figure 5 Optionally, the second gripper 2 has a positioning protrusion 21 on its side facing the first gripper 1, and the positioning protrusion 21 is located at the first end of the second gripper 2. When the first end of the first gripper 1 moves relative to the second gripper 2 to abut against the positioning protrusion 21, the first end of the first gripper 1 and the first end of the second gripper 2 together clamp and fix a set of exposed straight sections 42 of the copper wire that only pass through the opening 3 of the second gripper 2.
[0049] In this embodiment, based on the extension direction of the opening 3, that is, the first direction being the X-axis direction, the axial direction of the flat wire stator can be the Z-axis direction. The first clamp 1 can be specifically set on the upper side of the second clamp 2 (on the side of the positive Z-axis direction). The first end of the upper side of the second clamp 2 (that is, its end in the positive X-axis direction) is provided with a positioning protrusion 21. When the first clamp 1 moves relative to the second clamp 2 in the positive X-axis direction, when the first end of the first clamp 1 abuts against the positioning protrusion 21 at the first end of the second clamp 2, it indicates that the first clamp 1 and the second clamp 2 have clamped and fixed a group of exposed straight copper wire segments 42 that only pass through the opening 3 of the second clamp 2. By limiting the first clamp 1 with the positioning protrusion 21, it can prevent the first clamp 1 and the second clamp 2 from clamping the group of exposed straight copper wire segments 42 too much, and avoid damaging the exposed straight copper wire segments 42.
[0050] Specifically, combined Figure 4-5 For example, when it is necessary to clamp and position the exposed straight section 42 of the fourth group of copper wires at a certain indexing position, the through 3 of the second jaw 2 can be fitted onto the exposed straight section 42 of the fourth group of copper wires at that indexing position, while the first jaw 1 is located on the side of the exposed straight section 42 of the fourth group of copper wires away from the axis of the stator core 41; then the first jaw 1 can be moved relative to the second jaw 2 in the positive X-axis direction until the first end of the first jaw 1 abuts against the positioning protrusion 21 of the first end of the second jaw 2, thereby realizing the clamping and positioning of the exposed straight section 42 of the fourth group of copper wires by the first end of the first jaw 1 and the first end of the second jaw 2.
[0051] See Figure 5-6 Optionally, the first end of the first gripper 1 has a protruding first protrusion 11, which is inserted into the opening 3 of the second gripper 2, and the first protrusion 11 is used to move along the opening 3 of the second gripper 2.
[0052] In this embodiment, for example, the first end of the first gripper 1 is provided with a downwardly protruding first protrusion 11. The first protrusion 11 is inserted into the through-hole 3 of the second gripper 2. By sliding the first protrusion 11 in the through-hole 3 of the second gripper 2 along the X-axis direction, the stability of the first gripper 1 when moving relative to the second gripper 2 can be improved, and the deviation of the first gripper 1 when moving can also be prevented.
[0053] Furthermore, by setting the first protrusion 11, the contact area between the first end of the first clamp 1 and the exposed straight section 42 of the copper wire can be increased, and the contact area between the first end of the first clamp 1 and the first end of the second clamp 2 and the corresponding set of exposed straight sections 42 of the copper wire can be made approximately the same. This can improve the front-to-back force balance when each set of exposed straight sections 42 of the copper wire is clamped, prevent slight twisting when each set of exposed straight sections 42 of the copper wire is clamped, and thus ensure the reliability of subsequent welding.
[0054] See Figure 1 and Figure 3 Optionally, the flat wire stator welding fixture further includes a main power telescopic component 5 and a first power telescopic component (not shown in the figure). The main power telescopic component 5 is driven to be connected to the second gripper 2, and the main power telescopic component 5 is driven to be connected to the first gripper 1 through the first power telescopic component. The telescopic directions of the main power telescopic component 5 and the first power telescopic component are both parallel to the extension direction of the opening 3, that is, parallel to the first direction.
[0055] In this embodiment, the position of the main power telescopic component 5 is fixed. The second gripper 2 and the first power telescopic component are respectively connected to the movable end of the main power telescopic component 5. That is, when the main power telescopic component 5 extends or retracts along the first direction, it can drive the second gripper 2, the first power telescopic component, and the first gripper 1 connected to the first power telescopic component to move together along the first direction. Moreover, the extension and retraction direction of the first power telescopic component is also parallel to the first direction, that is, the first power telescopic component only drives the first gripper 1 to move in the X-axis direction. Therefore, the first gripper 1 and the second gripper 2 can only move in the X-axis direction. Ultimately, the degree of automation is improved, thereby improving the movement accuracy of the first gripper 1 and the second gripper 2 and improving the welding operation efficiency. Furthermore, the first power telescopic component can drive the first gripper 1 to move relative to the second gripper 2, thereby realizing the adjustment of the size of the non-overlapping area of the opening 3 of the second gripper 2 and the opening 3 of the first gripper 1, and realizing the clamping action of the first end of the first gripper 1 and the first end of the second gripper 2 on a certain group of exposed straight sections 42 of copper wire.
[0056] Based on this, the flat wire stator welding fixture can be used in conjunction with the stator rotation lifting mechanism (not shown in the figure). Specifically, the flat wire stator is placed on the upper side (on the positive Z-axis side) of the stator rotation lifting mechanism. The rotation lifting mechanism can drive the flat wire stator to rise and fall, or drive the flat wire stator to rotate around its own axis. Then, the flat wire stator welding fixture is fixed on one circumferential side of the flat wire stator.
[0057] For example, when it is necessary to clamp and position the first set of exposed copper wire straight segments 42 at a certain indexing position, the indexing position of the flat wire stator can be rotated to the state corresponding to the welding fixture of the flat wire stator by the rotary lifting mechanism; then the relative position of the first jaw 1 and the second jaw 2 can be adjusted by the first power telescopic component, thereby adjusting the size of the non-overlapping area of the opening 3 of the second jaw 2 and the opening 3 of the first jaw 1, so that the non-overlapping area of the two openings 3 can accommodate only one set of exposed copper wire straight segments 42; then the second jaw 2 and the first jaw 1 can be moved together by the main power telescopic component 5, so that the non-overlapping area of the two openings 3 can be moved to the indexing position. The first set of copper wire exposed straight segments 42 is positioned directly above the first set of copper wires at the indexing position. Then, the flat wire stator is raised by a rotating lifting mechanism (moving along the positive Z-axis) so that the first set of copper wire exposed straight segments 42 at this indexing position is inserted upward into the area where the two through-holes 3 do not overlap. At the same time, the second set of copper wire exposed straight segments 42, the third set of copper wire exposed straight segments 42, and the fourth set of copper wire exposed straight segments 42 are inserted into the area where the two through-holes 3 overlap. Then, the first clamp 1 is moved by the first power telescopic component so that the first end of the first clamp 1 and the first end of the second clamp 2 together complete the radial clamping and positioning of the first set of copper wire exposed straight segments 42 at this indexing position.
[0058] See Figure 5-6 Optionally, the flat wire stator welding fixture further includes an intermediate connecting rod 6. The first clamp 1 is disposed on the side of the second clamp 2 away from the stator core 41. The side of the first clamp 1 away from the second clamp 2 has two spaced-apart protrusions 12. The opening 3 of the first clamp 1 is located between the two protrusions 12. One end of the intermediate connecting rod 6 is located between the two protrusions 12 and connected to the first clamp 1. The other end of the intermediate connecting rod 6 is connected to the first power telescopic member.
[0059] In this embodiment, the first power telescopic component can be a servo electric cylinder. When the first gripper 1 and the second gripper 2 radially clamp a group of exposed straight sections 42 of copper wire through the movement of the servo electric cylinder, the actual movement position of the first gripper 1 can be fed back to the PLC through the servo motor encoder in the servo electric cylinder to form a closed-loop control, thereby ensuring the consistency of clamping each group of exposed straight sections 42 of copper wire.
[0060] In this embodiment, when the first power telescopic component is a servo electric cylinder, preferably, the upper side of the first gripper 1 has two spaced-apart protrusions 12, the opening 3 of the first gripper 1 is located between the two protrusions 12, and an intermediate connecting rod 6 is provided between the two protrusions 12, so that the first gripper 1 can be connected to the servo electric cylinder through the intermediate connecting rod 6. This is because the mounting holes on the servo electric cylinder and the mounting holes on the first gripper 1 may not match, so the two are indirectly connected by the intermediate connecting rod 6. When the first gripper 1 is connected to the servo electric cylinder through the intermediate connecting rod 6, the intermediate connecting rod 6 can move between the two protrusions 12 so that the mounting hole at one end of the intermediate connecting rod 6 corresponds to the mounting hole of the first gripper 1, and at the same time, the mounting hole at the other end of the intermediate connecting rod 6 corresponds to the mounting hole of the servo electric cylinder. In addition, the intermediate connecting rod 6, which serves as the power transmission component between the servo electric cylinder and the first gripper 1, has bosses on both sides. These bosses can also limit the intermediate connecting rod 6 in the radial Y-axis direction, ensuring that the power transmission is only in the X-axis direction, thereby improving the power transmission efficiency.
[0061] See Figure 7-11 Optionally, the flat wire stator welding fixture further includes two third grippers 7 and two second power telescopic members 8 symmetrically arranged about the extension direction of the through-hole 3. The two second power telescopic members 8 are fixed relative to the second grippers 2, just as the second grippers 2 are connected to the main power telescopic member 5; and the two second power telescopic members 8 are drivenly connected to the corresponding third grippers 7. The two second power telescopic members 8 are used to drive the two third grippers 7 to perform a clamping action in a third direction, so as to clamp at least one set of exposed straight copper wire segments 42 that only penetrate the through-hole 3 of the second grippers 2; wherein the third direction is perpendicular to the first direction and the second direction, respectively. With the first direction being the X-axis direction and the second direction being the Z-axis direction, the third direction is the Y-axis direction.
[0062] In this embodiment, after the first end of the first jaw 1 and the first end of the second jaw 2 clamp a certain group of exposed straight copper wire segments 42 longitudinally, the two second power telescopic members 8 can drive the two third jaws 7 to move relative to each other in the third direction, so as to clamp the exposed straight copper wire segments 42 in the stator core circumferential direction, ensuring that the two exposed straight copper wire segments 42 in this group are aligned in the third direction, further improving the welding quality, welding yield and pull-out force of the weld.
[0063] See Figure 8 , Figure 10-11Optionally, the first gripper 1 is disposed on the side of the second gripper 2 away from the stator core 41 of the flat wire stator; the third gripper 7 includes a clamping part 71 and a connecting part 72, the connecting part 72 is located on the side of the first gripper 1 away from the second gripper 2, the connecting part 72 is connected to the second power telescopic member 8, the second end of the clamping part 71 is connected to the connecting part 72, the first end of the clamping part 71 gradually tilts towards the first end 41 of the second gripper 2 and contacts the side of the first end of the second gripper 2 facing the first gripper 1.
[0064] In this embodiment, since the third jaw 7 needs to clamp each group of exposed copper wire straight segments 42 in the stator core circumferential direction, at least a portion of each third jaw 7 needs to be located between two adjacent indexing positions to ensure that it does not interfere with multiple groups of exposed copper wire straight segments 42 at other indexing positions. Specifically, the clamping portion 71 of the third jaw 7 is located between two adjacent indexing positions to clamp at least one group of the exposed copper wire straight segments 42 that only penetrate the through-hole 3 of the second jaw 2.
[0065] For example Figure 10 As shown, assuming that the multiple sets of exposed copper wire straight segments 42 at the indexing position corresponding to the first direction are the first row of exposed copper wire straight segments 42, the multiple sets of exposed copper wire straight segments 42 at the adjacent indexing position on one side of the circumferential direction are the second row of exposed copper wire straight segments 42, and the multiple sets of exposed copper wire straight segments 42 at the adjacent indexing position on the other side of the circumferential direction are the third row of exposed copper wire straight segments 42. When the first row of exposed copper wire straight segments 42 corresponds to the first direction, if it is necessary to clamp each set of exposed copper wire straight segments 42 in the circumferential direction of the stator core, then at least a part of a third jaw 7, that is, the clamping part 71, needs to be located between the first row of exposed copper wire straight segments 42 and the second row of exposed copper wire straight segments 42, and the clamping part 71 of another third jaw 7 needs to be located between the first row of exposed copper wire straight segments 42 and the third row of exposed copper wire straight segments 42. Therefore, in this embodiment, the clamping part 71 of the third claw 7 can be designed as a long and narrow structure, so that the clamping part 71 of the third claw 7 can be located between the exposed straight segments 42 of the copper wires in two adjacent rows and move upward in the third direction.
[0066] In this embodiment, the clamping part 71 is connected to the second power telescopic member 8 through the connecting part 72. The connecting part 72 is located on the side of the first clamp 1 away from the second clamp 2, that is, on the upper side of the first clamp 1, and can also be located outside the outer peripheral wall of the positioning iron core, so as to ensure that the connecting part 72 will not interfere with the exposed straight section 42 of the copper wire when the third clamp 7 moves upward, nor will it interfere with the first clamp 1 and the second clamp 2. On this basis, the connecting part 72 can be a plate-like structure with a larger size to improve the overall strength of the third clamp 7 and also improve the connection strength between the third clamp 7 and the second power telescopic member 8.
[0067] In this embodiment, as Figure 8 and Figure 11 The second end of the clamping part 71 is connected to the connecting part 72. The first end of the clamping part 71 gradually tilts towards the first end of the second jaw 2 and contacts the side (upper side) of the first end of the second jaw 2 facing the first jaw 1. At this time, on the one hand, the third jaw 7, the second jaw 2, and the first jaw 1 are arranged sequentially along the second direction, which can improve the integration of the third jaw 7, the first jaw 1, and the second jaw 2 and reduce the space occupation. On the other hand, after the first end of the clamping part 71 of the third jaw 7 tilts downward, the clamping positions of the two third jaws 7 on the exposed straight section 42 of the copper wire are adjacent to the clamping positions of the second jaw 2 and the first jaw 1. That is to say, the clamping positions of these jaws are relatively concentrated. Thus, for certain product models, even if the length of the exposed straight section 42 of the copper wire in the flat wire stator is very small (the clamping area is very short), the clamping positions of these jaws are relatively concentrated, which can achieve longitudinal and lateral clamping of the short exposed straight section 42 of the copper wire. This improves the versatility of the flat wire stator welding fixture for different product models of flat wire stators, such as Hair-pin model products (hairpin type stator), I-pin model products (I-type stator), Umini-pin model products (mini U-type stator), etc.
[0068] Optionally, the first jaw 1 and the second jaw 2 can be made of BOHLER W360 material, which can improve the strength and wear resistance of the two jaws. The thickness of the second jaw 2, located below the first jaw 1 (on the negative Z-axis side), can be 2.5mm. This ultra-thin jaw design reduces costs. Furthermore, for certain product models, even if the length of the exposed straight section 42 of the copper wire in the flat wire stator is very small (the clamping area is short), this ultra-thin jaw design can further improve the versatility of flat wire stators for these product models.
[0069] See Figure 8 and Figure 11Optionally, the first end of the first gripper 1 is provided with a relief slope 13 for avoiding the gripping part 71; and / or, along the third direction, the size of the gripping part 71 is smaller than the size of the connecting part 72.
[0070] In this embodiment, since the first end of the clamping part 71 is inclined downwards, in order to ensure that the clamping part 71 in this inclined direction does not interfere with the first clamping claw 1 on the upper side of the second claw 2, a clearance slope 13 can be provided at the end of the first claw 1 away from the main power telescopic member 5, that is, at the first end of the first claw 1, to avoid the clamping part 71 in the inclined state and prevent interference. Moreover, along the third direction, the size of the clamping part 71 can be smaller than the size of the connecting part 72, that is, the clamping part 71 is a long and narrow structure, so that it can be located between the exposed straight segments 42 of two adjacent rows of copper wires and move in the third direction.
[0071] See Figure 10-11 Optionally, the first end of the clamping part 71 is provided with a second protrusion 711, the protrusion direction of the second protrusion 711 is parallel to the third direction, and the second protrusion 711 is used to insert between two adjacent sets of exposed straight sections 42 of copper wires in the extension direction of the through port 3; the second protrusions 711 of the two clamping parts 71 are used to abut against each other to restrict the clamping movement of the two third claws 7.
[0072] In this embodiment, the front ends of the two clamping parts 71 are also provided with second protrusions 711 protruding towards each other. During the process of the two third jaws 7 moving relative to each other to clamp a certain group of exposed straight copper wire segments 42 laterally, the two second protrusions 711 can be inserted between two adjacent groups of exposed straight copper wire segments 42 at the pitch circle. When the two protrusions contact each other, it means that the two third jaws 7 have completed the clamping of a certain group of exposed straight copper wire segments 42 in the stator core circumferential direction, which can prevent excessive clamping and damage to the copper wire.
[0073] Optionally, the second power telescopic component 8 can be a cylinder, and this cylinder is connected to a booster cylinder. The left and right cylinders use the air source of the booster cylinder for clamping to ensure sufficient clamping force; the position of the third gripper 7 can also be monitored in real time through the analog switch of the cylinder to avoid the problem of insufficient clamping pressure of the left and right cylinders when the tension of the straight section of the outer segment of the copper wire is too large due to the influence of the bent section of the copper wire (not shown in the figure).
[0074] See Figure 8 and Figure 11 The clamping part 71 has a rib plate 712 protruding from the side away from the second gripper 2, and the rib plate 712 extends from the second end of the clamping part 71 toward its first end.
[0075] In this embodiment, the clamping part 71 is relatively long and narrow, resulting in relatively weak strength. To improve structural strength, upwardly protruding ribs 712 can be provided between the front and rear ends of the clamping part 71 to strengthen the structure. Furthermore, since the ribs 712 are located on the side of the clamping part 71 away from the second jaw 2, i.e., on the upper side of the clamping part 71, when welding the exposed straight sections 42 of copper wires at a certain indexing position, the ribs 712 on both sides can also block welding slag, preventing it from splashing onto the exposed straight sections 42 of copper wires at adjacent indexing positions. The effect of blocking welding slag is even better when the top of the ribs 712 is higher than the end face of the exposed straight section 42 of the copper wire.
[0076] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" and "second" may explicitly or implicitly include at least one of that feature. Unless otherwise specified, the term "multiple" means at least two.
[0077] Although the present invention has been disclosed above, its protection scope is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention, and all such changes and modifications will fall within the protection scope of the present invention.
Claims
1. A flat wire stator welding fixture, characterized in that, The device includes a first clamp (1) and a second clamp (2), which are arranged sequentially along a second direction and are movably connected to each other along a first direction. The first clamp (1) and the second clamp (2) are respectively provided with a through-hole (3) for inserting the exposed straight section (42) of the copper wire of the flat wire stator. The through-hole (3) is parallel to the second direction and the extension direction of the through-hole (3) is parallel to the first direction. The first clamp (1) and the second clamp (2) are used to move relative to each other to jointly clamp the exposed straight section (42) of the copper wire passing through the through-hole (3). The first direction is perpendicular to the second direction.
2. The flat wire stator welding fixture according to claim 1, characterized in that, Both the first jaw (1) and the second jaw (2) include a first end extending from the same end along the first direction; the first end of the first jaw (1) is used to move along the first direction toward the first end of the second jaw (2) to clamp and fix a set of exposed straight segments (42) of copper wire that only pass through the opening (3) of the second jaw (2) together with the first end of the second jaw (2).
3. The flat wire stator welding fixture according to claim 2, characterized in that, The second gripper (2) has a positioning protrusion (21) on its side facing the first gripper (1), and the positioning protrusion (21) is located at the first end of the second gripper (2). When the first end of the first gripper (1) moves relative to the second gripper (2) to abut against the positioning protrusion (21), the first end of the first gripper (1) and the first end of the second gripper (2) together clamp and fix a set of exposed straight sections (42) of copper wire that only pass through the opening (3) of the second gripper (2).
4. The flat wire stator welding fixture according to claim 2, characterized in that, The first end of the first gripper (1) has a first protrusion (11) protruding out. The first protrusion (11) is inserted into the opening (3) of the second gripper (2), and the first protrusion (11) is used to move along the opening (3) of the second gripper (2).
5. The flat wire stator welding fixture according to claim 2, characterized in that, It also includes a main power telescopic component (5) and a first power telescopic component. The main power telescopic component (5) is driven to be connected to the second gripper (2). The main power telescopic component (5) is driven to be connected to the first gripper (1) through the first power telescopic component. The telescopic directions of the main power telescopic component (5) and the first power telescopic component are both parallel to the first direction.
6. The flat wire stator welding fixture according to any one of claims 2-5, characterized in that, It also includes two third grippers (7) and two second power telescopic members (8) symmetrically arranged about the extension direction of the opening (3). The two second power telescopic members (8) are respectively fixed relative to the second grippers (2), and the two second power telescopic members (8) are respectively driven connected to the third grippers (7) on the corresponding side. The two second power telescopic members (8) are used to drive the two third grippers (7) to perform a clamping action in a third direction, so as to clamp at least a set of exposed straight segments (42) of copper wires that only pass through the opening (3) of the second grippers (2); wherein, the third direction is perpendicular to the first direction and the second direction respectively.
7. The flat wire stator welding fixture according to claim 6, characterized in that, The first gripper (1) is located on the side of the second gripper (2) away from the stator core (41) of the flat wire stator; the third gripper (7) includes a clamping part (71) and a connecting part (72). The connecting part (72) is located on the side of the first gripper (1) away from the second gripper (2). The connecting part (72) is connected to the second power telescopic member (8). The second end of the clamping part (71) is connected to the connecting part (72). The first end of the clamping part (71) gradually tilts towards the first end of the second gripper (2) and contacts the side of the first end of the second gripper (2) facing the first gripper (1).
8. The flat wire stator welding fixture according to claim 7, characterized in that, The first end of the first gripper (1) is provided with a relief slope (13) for avoiding the gripping part (71); And / or, along the third direction, the size of the clamping part (71) is smaller than the size of the connecting part (72).
9. The flat wire stator welding fixture according to claim 7, characterized in that, The first end of the clamping part (71) is provided with a second protrusion (711). The protrusion direction of the second protrusion (711) is parallel to the third direction. The second protrusion (711) is used to insert between two adjacent sets of exposed straight copper wire segments (42) in the extension direction of the through (3). The second protrusions (711) of the two clamping parts (71) are used to abut against each other to restrict the clamping movement of the two third jaws (7).
10. The flat wire stator welding fixture according to claim 7, characterized in that, The clamping part (71) has a rib plate (712) protruding from the side away from the second gripper (2), and the rib plate (712) extends from the second end of the clamping part (71) toward its first end.