A feeding device for flat wire motor coil production

Abstract

This invention proposes a feeding device for producing flat wire motor coils, including a wire feeding mechanism for feeding out strips of flat copper wire; a horizontal straightening wheel assembly and a vertical straightening wheel assembly, arranged side-by-side above the wire feeding mechanism, with their centers on the same horizontal line; and a floating tensioning mechanism, located between the wire feeding mechanism and the horizontal straightening wheel assembly, including a tensioning component and a floating component capable of driving the tensioning component to move horizontally. The tensioning component can move horizontally under the traction pressure of the flat copper wire. The wire feeding mechanism of this invention enables automatic feeding of flat copper wire. The coordinated action of the horizontal and vertical straightening wheel assemblies achieves synchronous straightening of the bidirectional bending of the flat copper wire. The floating tensioning mechanism is designed to adjust its position in real time according to the traction force of the flat copper wire, thereby eliminating sudden tension changes caused by fluctuations in the front-end feeding or rear-end pulling speed, and preventing the flat copper wire from stretching, deforming, or breaking.

Description

Technical Field

[0001] This utility model relates to the field of flat wire motor coil processing technology, specifically, it demonstrates a feeding device for the production of flat wire motor coils. Background Technology

[0002] Against the backdrop of the rapid development of new energy vehicles and high-efficiency energy-saving motors, flat wire motors are receiving increasing attention due to their advantages such as high power density, low noise, and high efficiency. One of the core aspects of flat wire motors lies in their unique wire forming process, which is related to production costs and manufacturing efficiency.

[0003] The wires used in flat-wire motors are typically called "flat copper wire" or "rectangular copper wire." This type of wire is flat in shape, unlike traditional round wires, and can effectively increase the slot fill factor of the motor, thereby improving its power density and efficiency.

[0004] In the manufacturing process of flat wire motors, there is a step known in the industry as coil forming, which mainly involves the production of flat wires for the stator core. The flat copper wires need to undergo a series of processes such as straightening, removing the enamel coating, cutting, and forming to finally form the coil.

[0005] Currently, the feeding and straightening of flat copper wires are done manually using straightening tools. However, the straightness or shape produced by this method is difficult to meet the requirements, which affects production efficiency, wastes production materials, and increases production costs. Utility Model Content

[0006] The purpose of this invention is to provide a feeding device for the production of flat wire motor coils, which can replace manual labor in straightening and feeding flat copper wires.

[0007] The technical solution is as follows:

[0008] A feeding device for producing flat wire motor coils includes:

[0009] The lead-out mechanism is used to guide out strips of flat copper wire;

[0010] A horizontal straightening wheel assembly and a vertical straightening wheel assembly are arranged side by side above the wire output mechanism. The horizontal straightening wheel assembly is used to horizontally straighten flat copper wires, and the vertical straightening wheel assembly is used to vertically straighten flat copper wires. The centers of the horizontal straightening wheel assembly and the vertical straightening wheel assembly are on the same horizontal line.

[0011] A floating tensioning mechanism is disposed between the lead-out mechanism and the transverse straightening wheel assembly. It includes a tensioning component and a floating component that can drive the tensioning component to move horizontally. The flat copper wire is led out from the lead-out mechanism and passes around the tensioning component before passing through the transverse straightening wheel assembly and the longitudinal straightening wheel assembly in sequence. The tensioning component can move horizontally under the traction pressure of the flat copper wire.

[0012] In addition, the above embodiments of this utility model may also have the following additional technical features:

[0013] According to one embodiment of the present invention, a horizontal guide mechanism is further provided at the front end of the transverse straightening wheel assembly, so that the flat copper wire flowing out from the tensioning member enters the transverse straightening wheel assembly in a horizontal posture. This primarily ensures that the flat copper wire can enter the transverse straightening wheel assembly in an almost horizontal posture.

[0014] Based on the above solution, the horizontal guide mechanism includes a traction wheel, and a pressure seat and a base arranged vertically and capable of being closed or separated. The bottom surface of the pressure seat and the top surface of the base are respectively provided with an upper groove and a lower groove, which, when closed, form a channel for the flat copper wire to pass through. This mainly solves the positioning problem of the flat copper wire before entering the horizontal straightening wheel assembly, forcibly restricting the guide posture of the flat copper wire towards the horizontal straightening wheel assembly.

[0015] According to one embodiment of this utility model, the wire feeding mechanism includes a carrier substrate and one or more sets of feeding rollers. A linear drive module capable of driving the carrier substrate to perform horizontal displacement is provided at the lower part of the carrier substrate. A pair of rollers, both rotatably arranged, are provided on the carrier substrate for vertically supporting the feeding rollers. One of the rollers is driven to rotate by a power unit. The position of the carrier substrate is adjusted by the linear drive module to ensure that the flat copper wires on it correspond to the horizontal straightening roller assembly and the vertical straightening roller assembly. Furthermore, the design of multiple sets of feeding rollers supports uninterrupted feeding.

[0016] Based on the above scheme, limiting protrusions are provided on both ends of the roller shaft, and a pair of anti-roll bars are provided above the outer side of the pair of roller shafts. During the rolling of the feed rollers, the feed rollers do not come into contact with the anti-roll bars. This is mainly a protective design to prevent the feed rollers from leaving the work station.

[0017] According to one embodiment of this utility model, both the transverse straightening wheel assembly and the longitudinal straightening wheel assembly include a plurality of fixed straightening wheels and a plurality of movable adjusting straightening wheels, which are arranged side by side. The movable adjusting straightening wheels can adjust the pressure for different wire thicknesses / hardnesses, preventing the flat copper wire from being over-straightened.

[0018] Based on the above scheme, several fixed straightening wheels and several movable adjusting straightening wheels are jointly mounted on a support plate. The movable adjusting straightening wheels are slidably embedded in the support plate via sliding bodies. An auxiliary side plate is also provided on the support plate, and several adjusting screws are threadedly connected to the auxiliary side plate. The other end of each adjusting screw is correspondingly connected to a sliding body. The adjusting screws enable rapid control of the displacement of the movable adjusting straightening wheels.

[0019] According to one embodiment of the present invention, the tensioning component includes a plate with a semi-arc structure and a mounting frame for mounting the plate, the mounting frame being disposed on the floating assembly; a plurality of spaced and rotatable contact rollers are arranged along the extending direction on the outer surface of the plate. The design of the contact rollers can reduce scratching of the flat copper wire, and the design of the arc-shaped plate can make the tension distribution uniform.

[0020] Based on the above scheme, the floating component includes:

[0021] A floating slide rail is arranged horizontally, on which a floating slider is slidably mounted by snap-fit, and the floating slider is connected to the mounting frame;

[0022] The counterweight is slidably mounted on a vertical slide rail by means of a snap-fit ​​connection;

[0023] Support rollers are positioned between the floating slide rail and the counterweight;

[0024] The traction line has its two ends connected to the mounting frame and the counterweight respectively, and the middle of the traction line passes around the support roller.

[0025] The stable tension is mainly provided by the counterweight, which is independent of the sensor.

[0026] Based on the same solution, blocking posts are respectively installed on both sides of the floating slide rail, and the blocking posts can abut against the mounting frame. This prevents the mounting frame from over-travel and constitutes maximum travel protection.

[0027] Compared with the prior art, the beneficial effects of this utility model are as follows: the wire feeding mechanism realizes automatic feeding of flat copper wire, and the synergistic action of the transverse straightening wheel assembly and the longitudinal straightening wheel assembly realizes synchronous straightening of the bidirectional bending of the flat copper wire. The design of the floating tensioning mechanism can adjust the position in real time according to the traction force of the flat copper wire, thereby eliminating the sudden tension caused by the fluctuation of the front end wire feeding or the rear end wire pulling speed, and avoiding the stretching deformation or breakage of the flat copper wire; thus realizing the automated straightening and feeding process of flat copper wire. Attached Figure Description

[0028] Figure 1 This is a front view schematic diagram of a feeding device for producing flat wire motor coils according to an embodiment of this utility model;

[0029] Figure 2 This is an isometric schematic diagram of a feeding device for producing flat wire motor coils according to an embodiment of the present invention;

[0030] Figure 3 These are schematic diagrams related to the transverse straightening wheel assembly, the longitudinal straightening wheel assembly, and the horizontal guide mechanism in embodiments of this utility model;

[0031] Figure 4This is a schematic diagram of the floating tensioning mechanism according to an embodiment of the present invention;

[0032] The following are the relevant markings in the attached diagram: 1-Cable delivery mechanism, 2-Transverse straightening roller assembly, 3-Vertical straightening roller assembly, 4-Tensioning component, 5-Floating component, 6-Horizontal guide mechanism, 7-Gantry frame body; 11-Bearing base plate, 12-Cable feeding roller, 13-Linear drive module, 14-Roller, 15-Power unit, 16-Anti-roll bar, 141-Limiting protrusion; 21-Fixed straightening roller, 22-Modible adjustable straightening roller, 23-Support plate, 24-Slider, 25- - Auxiliary side plate, 26- Adjusting screw; 41- Plate body, 42- Mounting frame, 43- Contact roller; 51- Floating slide rail, 52- Floating slider, 53- Counterweight block, 54- Vertical slide rail, 55- Support roller, 56- Traction line, 57- Blocking column; 61- Traction wheel, 62- Pressure seat, 63- Base, 64- Guide column, 65- Top plate, 66- Rod body, 67- Linkage rod body, 68- Elbow clamp, 621- Upper groove section, 631- Lower groove section. Detailed Implementation

[0033] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0034] Reference Figure 1 As shown in the figure, this utility model embodiment proposes a feeding device for the production of flat wire motor coils, mainly for the straightening and feeding of flat copper wires. The feeding device includes a wire output mechanism 1, a transverse straightening wheel assembly 2, a longitudinal straightening wheel assembly 3, and a floating tensioning mechanism. From a spatial distribution perspective, the wire output mechanism 1 is located below the actual workbench, while the floating tensioning mechanism, the transverse straightening wheel assembly 2, and the longitudinal straightening wheel assembly 3 are all located above the actual workbench and above the wire output mechanism 1, specifically with the aid of a gantry frame 7. The wire output mechanism 1 is mainly used to guide the flat copper wires in strips. The guided flat copper wires pass sequentially through the floating tensioning mechanism, the transverse straightening wheel assembly 2, and the longitudinal straightening wheel assembly 3.

[0035] The horizontal straightening wheel assembly 2 and the vertical straightening wheel assembly 3 are installed side by side at intervals on the top surface of the gantry frame 7 and above the cable outlet mechanism 1. The horizontal straightening wheel assembly 2 is used to horizontally straighten the flat copper wire, and the vertical straightening wheel assembly 3 is used to vertically straighten the flat copper wire. The centers of the horizontal straightening wheel assembly 2 and the vertical straightening wheel assembly 3 are on the same horizontal line.

[0036] The horizontal straightening wheel assembly 2 and the vertical straightening wheel assembly 3 are basically the same in structural design, except that their arrangement is different. The horizontal straightening wheel assembly 2 is used to provide straightening force in the left and right direction for the flat copper wire, while the vertical straightening wheel assembly 3 is used to provide straightening force in the up and down direction for the flat copper wire. In this way, the straightening action of the flat copper wire is achieved through the synergistic action of the horizontal straightening wheel assembly 2 and the vertical straightening wheel assembly 3.

[0037] Combination Figure 3 As shown in the diagram, specifically, both the transverse straightening wheel assembly 2 and the longitudinal straightening wheel assembly 3 include a number of corresponding fixed straightening wheels 21 and a number of movable adjusting straightening wheels 22. These fixed and movable straightening wheels 21 and 22 are arranged side-by-side. It is worth noting that the fixed and movable straightening wheels 21 and 22 on the transverse straightening wheel assembly 2 are arranged horizontally and rotatably, while those on the longitudinal straightening wheel assembly 3 are arranged vertically and rotatably. Both the fixed and movable straightening wheels 21 and 22 can rotate in their original positions, and the flat copper wire must pass between them. The purpose of designing the movable adjusting straightening wheels is primarily to control the tension between the fixed and movable straightening wheels, thus allowing for pressure adjustment for different wire thicknesses / hardnesses and preventing the flat copper wire from being over-straightened.

[0038] Several fixed straightening wheels 21 and several movable adjusting straightening wheels 22 are jointly mounted on a support plate 23, which is mounted on the gantry frame 7. The movable adjusting straightening wheels 22 are slidably embedded in the support plate 23 via sliding bodies 24, allowing the movable adjusting straightening wheels 22 to move slightly toward the fixed straightening wheels 21. An auxiliary side plate 25 is also provided on the support plate 23, and several adjusting screws 26 are threadedly connected to the auxiliary side plate 25. The other end of the adjusting screws 26 is connected to the sliding body 24. In this way, the displacement of the movable adjusting straightening wheels 22 can be quickly controlled by turning the adjusting screws 26, thereby flexibly adjusting the tightness between the fixed straightening wheels 21 and the movable adjusting straightening wheels 22 to better adapt to the thickness of the flat copper wire.

[0039] The floating tensioning mechanism is located between the lead-out end of the lead-out mechanism 1 and the front end of the transverse straightening wheel assembly 2. It mainly includes a tensioning component 4 and a floating component 5 that can drive the tensioning component 4 to move horizontally. After the flat copper wire is led out from the lead-out mechanism 1 and passes around the tensioning component 4, it passes through the transverse straightening wheel assembly 2 and the longitudinal straightening wheel assembly 3 in sequence. Under the traction pressure of the flat copper wire, the tensioning component 4 can move horizontally. The tension force of the flat copper wire is automatically adjusted during the transmission process by the horizontal movement of the tensioning component under the traction pressure of the flat copper wire. This is a stable tension control that cannot be achieved by traditional manual operation.

[0040] Combination Figure 4 As shown, the tensioning component 4 mainly includes a plate 41 with a semi-arc structure and a mounting frame 42 for mounting the plate 41. The upper end of the mounting frame 42 is set on the floating component 5 on the top surface of the gantry frame 7. The arc of the plate 41 protrudes outward. From the side view, the plate 41 is hook-shaped. Several spaced and rotatable contact rollers 43 are arranged on the outer side of the plate 41 along its extension direction. After the flat copper wire flows out from the wire exit mechanism 1, it will continue to be transmitted upward along the extension direction of the plate 41. The arc-shaped plate design can make the tension of the flat copper wire evenly distributed and flow along the preset trajectory, while the contact roller design can reduce the scratches during the transmission of the flat copper wire.

[0041] Continue to refer to Figure 4 The floating component 5 is designed as follows: A floating slide rail 51 is horizontally positioned, on which a floating slider 52 is slidably mounted in a snap-fit ​​manner. The floating slider 52 is connected to the mounting frame 42, meaning the mounting frame 42 can slide left and right relative to the floating slide rail 51 along with the floating slider 52. A counterweight 53 is slidably mounted on a vertical slide rail 54 in a snap-fit ​​manner, meaning the counterweight 53 can only move up and down. A support roller 55 is positioned between the floating slide rail 51 and the counterweight 53. A traction line 56 has its two ends connected to the mounting frame 42 and the counterweight 53 respectively, with the middle of the traction line 56 passing over the support roller 55. The floating slide rail 51, the vertical slide rail 54, and the support roller 55 are all mounted on the gantry frame 7. The counterweight and floating slider are linked, and gravity balance is achieved by the traction line passing over the support roller, which is more reliable and easier to maintain than a conventional spring mechanism.

[0042] To prevent excessive displacement of the mounting frame 42, a blocking column 57 is provided on each of the two outer ends of the floating slide rail 51. The blocking column 57 can abut against the top side of the mounting frame 42, and the two blocking columns form the maximum travel protection for the mounting frame.

[0043] The wire feeding mechanism 1 in this embodiment is not a conventional fixed wire feeding tray design, but a more flexible design, referring to... Figure 2As shown, the specific implementation scheme is as follows: It includes a horizontal support substrate 11 and one or more sets of feed rollers 12. If there are two or more feed rollers 12, they are arranged side-by-side. The feed rollers 12 are vertically positioned on the top surface of the support substrate 11. A linear drive module 13 is provided at the lower part of the support substrate 11 to drive it to perform horizontal displacement. The linear drive module 13 realizes the horizontal movement of the support substrate 11 so that the feed rollers 12 on it can be aligned with the floating component 5. A pair of feed rollers 12 are provided on the support substrate 11 for vertically supporting them and both can rotate. The rollers 14 are arranged so that the wire feeding rollers 12 are supported by a pair of rollers 14 and the lowest surface of the wire feeding rollers 12 will not contact the carrier substrate 11. One of the rollers 14 is driven to rotate by a power unit 15. The power unit 15 is a conventional design, such as consisting of a rotary motor, a drive pulley, a driven pulley, a synchronous belt, etc., to realize the rotation of the rollers 14, thereby realizing the rotational feeding of the wire feeding rollers 12. The linear drive module 13 adjusts the position of the carrier substrate 11 to ensure that the flat copper wires on it can correspond to the transverse straightening roller assembly 2 and the longitudinal straightening roller assembly 3. The design of multiple sets of wire feeding rollers can support uninterrupted feeding.

[0044] To further ensure the stability of the feeding roller 12 during rotation, limiting protrusions 141 are provided on both sides of the roller shaft 14. That is to say, the feeding roller 12 can be just sandwiched between the two limiting protrusions 141. A pair of anti-roll bars 16 are provided on the upper outer side of the pair of roller shafts 14. Through the cooperation of the limiting protrusions 141 and the anti-roll bars 16, the feeding roller is prevented from shifting laterally during the feeding process, preventing accidental detachment from the roller shaft and ensuring the normal operation of the feeding work.

[0045] In other possible implementations, in order to solve the positioning problem of the flat copper wire before entering the horizontal straightening roller assembly, a horizontal guide mechanism 6 is set at the front end of the horizontal straightening roller assembly, so that the flat copper wire flowing out from the tensioning component enters the horizontal straightening roller assembly in a horizontal posture, ensuring the continuous operation of the production line.

[0046] Combination Figure 3 As shown, the horizontal guide mechanism 6 is specifically designed to include a traction wheel 61, and a pressure seat 62 and a base 63 arranged vertically and capable of being joined or separated. The bottom end face of the pressure seat 62 and the top end face of the base 63 are respectively provided with an upper groove section 621 and a lower groove section 631. The upper groove section 621 and the lower groove section 631, which are joined together, form a channel for the flat copper wire to pass through. The upper groove section 621 and the lower groove section 631 forcibly restrict the guide posture of the flat copper wire toward the horizontal straightening wheel assembly 2.

[0047] A pair of guide posts 64 are vertically inserted into the pressure seat 62. The top of the guide post 64 is connected to a top plate 65, and the bottom of the guide post 64 is connected to the base 63. The top plate 65 and the base 63 are fixedly connected by a rod 66. A linkage rod 67 is movably inserted on the top plate 65. The top of the linkage rod 67 is connected to an elbow clamp 68. By manually rotating the elbow clamp 68, the linkage rod 67 is controlled to press the pressure seat 62 downward toward the base 63, thereby realizing the closing of the pressure seat 62 and the base 63.

[0048] The above descriptions are merely some embodiments of this utility model. For those skilled in the art, various modifications and improvements can be made without departing from the inventive concept of this utility model, and all such modifications and improvements fall within the protection scope of this utility model.

Claims

1. A feeding device for producing flat wire motor coils, characterized in that, include: The wire output mechanism (1) is used to output flat copper wires in strips; The horizontal straightening wheel assembly (2) and the vertical straightening wheel assembly (3) are arranged side by side above the wire output mechanism (1). The horizontal straightening wheel assembly (2) is used to straighten the flat copper wire horizontally, and the vertical straightening wheel assembly (3) is used to straighten the flat copper wire vertically. The centers of the horizontal straightening wheel assembly (2) and the vertical straightening wheel assembly (3) are on the same horizontal line. A floating tensioning mechanism is set between the lead-out mechanism (1) and the transverse straightening wheel assembly (2), including a tensioning component (4) and a floating component (5) that can drive the tensioning component (4) to move horizontally. The flat copper wire is led out from the lead-out mechanism (1) and passes around the tensioning component (4) and then passes through the transverse straightening wheel assembly (2) and the longitudinal straightening wheel assembly (3) in sequence. The tensioning component (4) can move horizontally under the traction pressure of the flat copper wire.

2. The feeding device for producing flat wire motor coils according to claim 1, characterized in that, It also includes a horizontal guide mechanism (6) provided at the front end of the transverse straightening wheel assembly (2), so that the flat copper wire flowing out from the tensioning member (4) enters the transverse straightening wheel assembly (2) in a horizontal posture.

3. The feeding device for producing flat wire motor coils according to claim 2, characterized in that, The horizontal guide mechanism (6) includes a traction wheel (61), and a pressure seat (62) and a base (63) arranged vertically and capable of being closed or separated. The bottom end face of the pressure seat (62) and the top end face of the base (63) are respectively provided with an upper groove section (621) and a lower groove section (631). The upper groove section (621) and the lower groove section (631) that are closed together form a channel for the flat copper wire to pass through.

4. The feeding device for producing flat wire motor coils according to claim 1, characterized in that, The wire feeding mechanism (1) includes a support base plate (11) and one or more sets of wire feeding rollers (12). The lower part of the support base plate (11) is provided with a linear drive module (13) that can drive it to make horizontal displacement. A pair of rollers (14) are provided on the support base plate (11) for vertically supporting the wire feeding rollers (12) and both of which are rotatably arranged. One of the rollers (14) is driven to rotate by a power unit (15).

5. The feeding device for producing flat wire motor coils according to claim 4, characterized in that, Both ends of the roller (14) are provided with limiting protrusions (141), and a pair of anti-roll bars (16) are provided above the outer side of the pair of rollers (14). During the rolling of the wire feeding roller (12), the wire feeding roller (12) does not come into contact with the anti-roll bars (16).

6. The feeding device for producing flat wire motor coils according to claim 1, characterized in that, The horizontal straightening wheel assembly (2) and the vertical straightening wheel assembly (3) each include a number of fixed straightening wheels (21) and a number of movable adjusting straightening wheels (22), with the fixed straightening wheels (21) and the movable adjusting straightening wheels (22) arranged side by side.

7. The feeding device for producing flat wire motor coils according to claim 6, characterized in that, Several fixed straightening wheels (21) and several movable adjusting straightening wheels (22) are jointly set on a support plate (23). Several movable adjusting straightening wheels (22) are slidably embedded in the support plate (23) through a sliding body (24). An auxiliary side plate (25) is also provided on the support plate (23). Several adjusting screws (26) are threadedly connected to the auxiliary side plate (25). The other end of the adjusting screws (26) is correspondingly connected to the sliding body (24).

8. The feeding device for producing flat wire motor coils according to claim 1, characterized in that, The tensioning component (4) includes a plate (41) with a semi-arc structure and a mounting frame (42) for mounting the plate (41). The mounting frame (42) is mounted on the floating component (5). Several spaced and rotatable contact rollers (43) are arranged on the outer side of the plate (41) along its extension direction.

9. The feeding device for producing flat wire motor coils according to claim 8, characterized in that, The floating component (5) includes: A floating slide rail (51) is arranged horizontally, on which a floating slider (52) is slidably mounted in a snap-fit ​​manner, and the floating slider (52) is connected to the mounting frame (42). The counterweight (53) is slidably mounted on a vertical slide rail (54) in a snap-fit ​​manner; A support roller (55) is disposed between the floating slide rail (51) and the counterweight (53); The traction line (56) is connected at both ends to the mounting frame (42) and the counterweight (53) respectively, and the middle part of the traction line (56) passes around the support roller (55).

10. A feeding device for producing flat wire motor coils according to claim 9, characterized in that, The floating slide rail (51) is provided with blocking columns (57) on both sides of its outer side. The blocking columns (57) can abut against the mounting frame (42).

Images