Stator coil shaping tool for flat wire motor

Abstract

This application provides a flat wire motor stator coil shaping fixture, relating to the field of flat wire motor processing. The fixture includes a fixture body, an electromagnetic auxiliary positioning module, a magnetic interface module, and an external shaping module. The electromagnetic auxiliary positioning module is embedded in the positioning surface where the fixture body contacts the coil and includes multiple evenly distributed electromagnetic units. The electromagnetic auxiliary positioning module also includes a power supply unit and a control module, with the electromagnetic units electrically connected to the control module via the power supply unit. This flat wire motor stator coil shaping fixture utilizes a magnetic field to achieve adaptive coil alignment, improving efficiency compared to traditional mechanical positioning and avoiding insulation damage caused by rigid contact. The composite structure of the permanent magnet and electromagnet cancels out the magnetic field when power is off, ensuring rapid coil release and reducing the risk of adhesion.

Description

Technical Field

[0001] This application relates to the field of flat wire motor processing technology, specifically to a flat wire motor stator coil shaping fixture. Background Technology

[0002] With the rapid development of new energy vehicles, industrial servo motors, and other fields, flat wire motors are widely used due to their advantages such as high power density and low loss. Stator coil shaping is a key process in the manufacturing of flat wire motors, and its tooling must meet stringent requirements such as high-precision positioning, rapid changeover, and coil protection.

[0003] Traditional coil forming fixtures have the following technical defects: relying on mechanical grippers or fixed pins for positioning can easily lead to misalignment between coil turns after forming, affecting the electromagnetic performance of the motor. In addition, the forming structure needs to be changed when the fixture is adapted to different specifications of coils, which takes a long time and is difficult to adapt to the needs of multi-variety small-batch production.

[0004] To address the aforementioned issues, a flat wire motor stator coil shaping fixture is proposed. Utility Model Content

[0005] (a) Technical problems to be solved

[0006] To address the shortcomings of existing technologies, this application provides a flat wire motor stator coil shaping fixture, which solves the problems mentioned in the background section.

[0007] (II) Technical Solution

[0008] To achieve the above objectives, this application provides the following technical solution: a flat wire motor stator coil shaping fixture, comprising a fixture body, an electromagnetic auxiliary positioning module, a magnetic interface module, and an external shaping module. The electromagnetic auxiliary positioning module is embedded in the positioning surface of the fixture body in contact with the coil and includes multiple sets of evenly distributed electromagnetic units. The electromagnetic auxiliary positioning module also includes a power supply unit and a control module, and the electromagnetic units are electrically connected to the control module through the power supply unit.

[0009] By adopting the above technical solution, the electromagnetic assisted positioning module achieves adaptive coil centering through magnetic field adsorption, which improves efficiency compared to traditional mechanical positioning and avoids insulation layer damage caused by rigid contact.

[0010] Preferably, the magnetic interface module includes a base connected to the output unit of the tooling body, a base block on the top of the external shaping module, a groove on the surface of the base that matches the base block, and a ring array of magnetic blocks embedded inside the groove. The magnetic interface module also includes a pneumatic locking mechanism, which includes cylinders fixedly installed on both sides of the base, a pin fixedly connected to the output end of the cylinder, and locking holes that match the pins on both sides of the base.

[0011] By adopting the above technical solution, the cylinder pushes the pin into the lock hole, forming a double fixation.

[0012] Preferably, a positioning pin is fixedly installed inside the groove, and a positioning hole adapted to the positioning pin is opened on the top of the base block.

[0013] By adopting the above technical solution, the positioning pin inside the groove is fitted with the positioning hole of the external shaping module with a clearance.

[0014] Preferably, the positioning pin has a tapered structure with a taper angle of 5°-15° and a wear-resistant coating on its surface.

[0015] By adopting the above technical solution, the positioning effect is improved by cooperating with the positioning hole in the tapered design of the positioning pin.

[0016] Preferably, a Hall sensor is provided in the groove of the magnetic interface module, and an indicator light is provided on the outside of the groove.

[0017] By adopting the above technical solution, the magnetic connection status of the base block of the external shaping module is detected, and the assembly completion signal is triggered by the indicator light.

[0018] Preferably, the electromagnetic unit is composed of a permanent magnet and an electromagnet. When the electromagnet is energized, it generates a magnetic field in the same direction as the permanent magnet, and when the power is off, the magnetic field directions cancel each other out.

[0019] By adopting the above technical solution, the electromagnet generates a magnetic field in the same direction as the permanent magnet when it is energized, and the magnetic field direction cancels out when the power is off.

[0020] Preferably, the magnetic block is a neodymium iron boron permanent magnet, its surface is covered with an insulating layer, and the magnetic poles of adjacent magnetic blocks are arranged in an alternating N-S configuration.

[0021] By adopting the above technical solution, multiple neodymium iron boron magnetic blocks are arranged in a ring inside the groove of the base, which can enhance the adsorption effect. The surface insulation layer is a polytetrafluoroethylene wear-resistant layer, which can reduce the wear of module disassembly and assembly.

[0022] Preferably, the control module integrates a current regulation unit.

[0023] By adopting the above technical solution, the control module integrates a PID controller and outputs an adjustable current through the current adjustment unit, which can adjust the attraction force of the electromagnetic unit according to the coil thickness.

[0024] Preferably, the tooling body is equipped with a pressure sensor.

[0025] By adopting the above technical solution, the pressure sensor is used to detect the magnetic connection status of the base block of the external shaping module, and the assembly completion signal is triggered by the indicator light.

[0026] (III) Beneficial Effects

[0027] This application provides a shaping fixture for the stator coils of a flat wire motor. It has the following beneficial effects:

[0028] 1. This flat wire motor stator coil shaping fixture uses an electromagnetic-assisted positioning module to achieve adaptive coil centering through magnetic field adsorption. Compared with traditional mechanical positioning, this improves efficiency and avoids insulation layer damage caused by rigid contact. The composite structure of permanent magnet and electromagnet cancels out the magnetic field when the power is off, ensuring rapid coil release and reducing the risk of adhesion.

[0029] 2. This flat wire motor stator coil shaping fixture is set up with a magnetic standardized interface and a pneumatic locking mechanism to form a dual fixation of magnetic force and mechanical force, which greatly shortens the changeover time, supports tool-less switching of multiple coil specifications, helps to improve work efficiency, and can adapt to the needs of multi-variety small-batch production. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0031] Figure 1 This is a three-dimensional structural diagram of the present application;

[0032] Figure 2 This is a three-dimensional structural diagram of the first type of magnetic interface module of this application;

[0033] Figure 3 This is a three-dimensional structural diagram of the second type of magnetic interface module in this application;

[0034] Figure 4 This is a partial three-dimensional structural diagram of the external shaping module of this application;

[0035] Figure 5 This is a partial three-dimensional structural diagram of the electromagnetic assisted positioning module of this application.

[0036] In the diagram: 1. Tooling body; 2. Electromagnetic auxiliary positioning module; 21. Electromagnetic unit; 211. Permanent magnet; 212. Electromagnet; 22. Power supply unit; 23. Control module; 231. Current adjustment unit; 24. Pressure sensor; 3. Magnetic interface module; 31. Base; 311. Groove; 32. Magnetic block; 33. Positioning pin; 34. Pneumatic locking mechanism; 341. Cylinder; 342. Pin; 35. Hall sensor; 36. Indicator light; 4. External shaping module; 41. Base block; 42. Locking hole; 43. Positioning hole. Detailed Implementation

[0037] The present application will be further described in detail below with reference to the accompanying drawings and embodiments.

[0038] Reference Figures 1 to 5 This application provides a flat wire motor stator coil shaping fixture, including a fixture body 1, an electromagnetic auxiliary positioning module 2, a magnetic interface module 3, and an external shaping module 4. The electromagnetic auxiliary positioning module 2 is embedded in the positioning surface of the fixture body 1 where it contacts the coil, and includes multiple sets of evenly distributed electromagnetic units 21. The electromagnetic auxiliary positioning module 2 also includes a power supply unit 22 and a control module 23. The electromagnetic units 21 are electrically connected to the control module 23 through the power supply unit 22. The control module 23 can read the RFID tag of the external shaping module 4 and automatically load the corresponding current curve and pressure threshold without manual setting.

[0039] In one aspect of this embodiment, the magnetic interface module 3 includes a base 31 connected to the output unit of the tooling body 1. The top of the external shaping module 4 is provided with a base block 41. The surface of the base 31 is provided with a groove 311 adapted to the base block 41. The groove 311 is embedded with a magnetic block 32 arranged in a ring array. The magnetic interface module 3 also includes a pneumatic locking mechanism 34. The pneumatic locking mechanism 34 includes a cylinder 341 fixedly installed on both sides of the base 31. The output end of the cylinder 341 is fixedly connected to a pin 342. Both sides of the base block 41 are provided with locking holes 42 adapted to the pin 342. When the Hall sensor 35 detects that the base block 41 of the external shaping module 4 is attracted into place, it triggers the cylinder 341 to push the pin 342 into the locking hole 42 (pin stroke 15mm, locking force ≥200N), forming a double fixation.

[0040] Reference Figure 3 and Figure 4 In one aspect of this embodiment, a positioning pin 33 is fixedly installed inside the groove 311, and a positioning hole 43 adapted to the positioning pin 33 is opened on the top of the base block 41. The positioning pin 33 inside the groove 311 is in clearance fit with the positioning hole 43 of the external shaping module 4.

[0041] The locating pin 33 adopts a tapered structure with a taper angle of 5°-15° and is coated with a wear-resistant layer, which is a polytetrafluoroethylene coating. The tapered design of the locating pin 33, together with the locating hole 43, improves the positioning effect.

[0042] A Hall sensor 35 is provided in the groove 311 of the magnetic interface module 3, and an indicator light 36 is provided on the outside of the groove 311. The indicator light 36 is used to detect the magnetic connection status of the base block 41 of the external shaping module 4 and to trigger the display of the assembly completion signal.

[0043] Reference Figure 1 and Figure 5 In one aspect of this embodiment, the electromagnetic unit 21 is composed of a permanent magnet 211 and an electromagnet 212. When the electromagnet 212 is energized, it generates a magnetic field in the same direction as the permanent magnet 211. When the power is off, the magnetic field directions cancel each other out.

[0044] The magnetic block 32 is a neodymium iron boron permanent magnet with an insulating layer on its surface. The magnetic poles of adjacent magnetic blocks 32 are arranged in an alternating N-S pattern. Multiple neodymium iron boron magnetic blocks 32 are arranged in a ring in the groove 311 of the base 31 to enhance the adsorption effect. The surface insulating layer is a polytetrafluoroethylene wear-resistant layer to reduce wear during module assembly and disassembly.

[0045] The control module 23 integrates a current regulation unit 231 and a PID controller. The current regulation unit 231 outputs an adjustable current of 0-5A, which can adjust the adsorption force of the electromagnetic unit 21 according to the coil thickness. The adsorption force range is 5-50N with an accuracy of ±0.5N.

[0046] The tooling body 1 is equipped with a pressure sensor 24. The pressure sensor 24 (Honeywell FSS series) is installed in the middle of the electromagnetic unit 21 to detect the contact pressure between the electromagnetic auxiliary positioning module 2 and the coil, and feeds it back to the control module 23 for closed-loop control.

[0047] All electrical devices in this plan are powered by an external power source.

[0048] Working principle: When using this flat wire motor stator coil shaping fixture, after placing the flat wire coil on the fixture positioning surface, the control module 23 applies a 3A current to the electromagnet 212, causing its magnetic field to superimpose in the same direction as the permanent magnet 211, generating a 35N attraction force to position the coil in the preset position. The pressure sensor 24 monitors the contact pressure in real time. If the pressure exceeds the tolerance (e.g., >40N), the current is automatically reduced to prevent the insulation layer from being crushed. After the base block 41 of the external shaping module 4 is installed with the base 31, the pneumatic locking mechanism 34 automatically locks it, and then the fixture performs shaping processing. After processing, the control module 23 cuts off the current to the electromagnet 212, and the magnetic field cancels out, reducing the attraction force to below 2N, allowing the flat wire coil to be easily removed. When the external shaping module 4 is replaced, the pneumatic locking mechanism 34 releases the base block 41. During disassembly, the Hall sensor 35 detects changes in magnetic flux. If the base block 41 is not completely detached, the indicator light 36 is triggered to prevent forced disassembly and damage to the interface.

[0049] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0050] Although embodiments of this application have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of this application, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A flat wire motor stator coil shaping fixture, comprising a fixture body (1), an electromagnetic auxiliary positioning module (2), a magnetic interface module (3), and an external shaping module (4), characterized in that: The electromagnetic auxiliary positioning module (2) is embedded on the positioning surface of the tooling body (1) in contact with the coil, and includes multiple sets of evenly distributed electromagnetic units (21). The electromagnetic auxiliary positioning module (2) also includes a power supply unit (22) and a control module (23). The electromagnetic units (21) are electrically connected to the control module (23) through the power supply unit (22). The magnetic interface module (3) includes a base (31) connected to the output unit of the tooling body (1). The top of the external shaping module (4) is provided with a base block (41). The surface of the base (31) is provided with a groove (311) that is adapted to the base block (41). The groove (311) is embedded with a magnetic block (32) arranged in a ring array. The magnetic interface module (3) also includes a pneumatic locking mechanism (34). The pneumatic locking mechanism (34) includes a cylinder (341) fixedly installed on both sides of the base (31). The output end of the cylinder (341) is fixedly connected with a pin (342). Both sides of the base block (41) are provided with a lock hole (42) that is adapted to the pin (342).

2. The flat wire motor stator coil shaping fixture according to claim 1, characterized in that: A positioning pin (33) is fixedly installed inside the groove (311), and a positioning hole (43) adapted to the positioning pin (33) is opened on the top of the base block (41).

3. The flat wire motor stator coil shaping fixture according to claim 2, characterized in that: The positioning pin (33) adopts a tapered structure with a taper angle of 5°-15° and is coated with a wear-resistant layer.

4. The flat wire motor stator coil shaping fixture according to claim 2, characterized in that: The magnetic interface module (3) has a Hall sensor (35) installed in the groove (311) and an indicator light (36) installed on the outside of the groove (311).

5. The flat wire motor stator coil shaping fixture according to claim 1, characterized in that: The electromagnetic unit (21) is composed of a permanent magnet (211) and an electromagnet (212). When the electromagnet (212) is energized, it generates a magnetic field in the same direction as the permanent magnet (211). When the power is off, the magnetic field directions cancel each other out.

6. The flat wire motor stator coil shaping fixture according to claim 1, characterized in that: The magnetic block (32) is a neodymium iron boron permanent magnet with an insulating layer covering its surface, and the magnetic poles of adjacent magnetic blocks (32) are arranged in an alternating N-S pattern.

7. The flat wire motor stator coil shaping fixture according to claim 1, characterized in that: The control module (23) integrates a current regulation unit (231).

8. The flat wire motor stator coil shaping fixture according to claim 1, characterized in that: The tooling body (1) is equipped with a pressure sensor (24).

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