molding apparatus

Abstract

The application discloses a forming device which comprises a base, a guide assembly, an upper plate and a processing mechanism, the processing mechanism comprises a lower die, an upper die, a lower die pin assembly and an upper die pin assembly, the guide assembly is connected with the base, the upper plate is movably connected with the guide assembly, the lower die is installed on the base, the lower die pin assembly is installed on the lower die, the upper die is installed on the upper plate, the upper die pin assembly is installed on the upper die, when the upper plate drives the upper die and the upper die pin assembly to move towards the base, the upper die can be matched with the lower die to punch and form a workpiece in the vertical direction, and the upper die pin assembly can be matched with the lower die pin assembly to punch and form the workpiece in the horizontal direction. The application integrates 2D forming and 3D forming together, greatly improves the efficiency of flat copper wire forming, omits the 2D forming process of the intermediate redundant "roof" part, improves the production efficiency and reduces the production cost.

Description

Technical Field

[0001] This application relates to the field of motor technology, specifically to a forming apparatus for flat copper wire hairpins for motors. Background Technology

[0002] Flat copper wire hairpin motors lead the industry trend with their advantages. Flat copper wire hairpin motors have high slot fill rate, high efficiency, light weight, and lower cost. However, the process of forming flat copper wire hairpins is very complex. Existing flat copper wire hairpin forming devices include 2D forming molds and 3D forming molds.

[0003] Currently, the main methods for achieving five-point forming of stator hairpins for flat copper wire motors are 2D five-point bending plus 3D forming. However, the production cycle time for 2D five-point bending is generally around 2.5 seconds, resulting in low production efficiency. Another method involves designing the 2D forming mold and the 3D forming mold as independent molds. During the flat copper wire forming process, the flat copper wire needs to be first 2D formed horizontally, then removed, and then 2D five-point forming is performed. Finally, the 2D-formed hairpin is placed into the 3D mold, causing the 2D-formed hairpin to undergo plastic deformation again, ultimately obtaining a 3D-shaped hairpin that meets the requirements. However, designing and developing the 2D mold and the 3D mold separately not only increases production costs but also results in low hairpin forming efficiency. Utility Model Content

[0004] In order to effectively overcome the problems existing in the prior art, the main objective of this application is to provide a molding device that can produce high efficiency and low cost.

[0005] To achieve the above objectives, this application specifically adopts the following technical solution:

[0006] This application provides a molding apparatus, the molding apparatus comprising:

[0007] Base;

[0008] Guide assembly, the guide assembly being connected to the base;

[0009] Upper plate, the upper plate being movably connected to the guide assembly; and

[0010] The processing mechanism includes a lower mold, an upper mold, a lower mold pin assembly, and an upper mold pin assembly. The lower mold is mounted on the base, the lower mold pin assembly is mounted on the lower mold, the upper mold is mounted on the upper plate, and the upper mold pin assembly is mounted on the upper mold.

[0011] When the upper plate moves the upper mold and the upper mold pin assembly toward the base, the upper mold can cooperate with the lower mold to stamp the workpiece in the vertical direction; the upper mold pin assembly can cooperate with the lower mold pin assembly to stamp the workpiece in the horizontal direction.

[0012] In some embodiments, the lower mold has a first processing surface on the side facing the upper mold, and the upper mold has a second processing surface on the side facing the lower mold;

[0013] The first processing surface includes a first arc-shaped surface, a second arc-shaped surface, and a third arc-shaped surface. The first arc-shaped surface and the third arc-shaped surface are respectively located on both sides of the second arc-shaped surface, and the side of the second arc-shaped surface closer to the third arc-shaped surface is higher than the side of the second arc-shaped surface closer to the first arc-shaped surface. The shape of the second processing surface is configured to match the shape of the first processing surface.

[0014] When the upper plate moves the upper mold toward the base, the second processing surface cooperates with the first processing surface to stamp the workpiece in the vertical direction.

[0015] In some embodiments, the lower mold pin assembly includes a shaping pin, a positioning pin, and a moving pin, and the upper mold pin assembly includes a pushing pin. The shaping pin, the positioning pin, and the moving pin are respectively installed on the lower mold, and the pushing pin is installed on the upper mold.

[0016] When the upper plate drives the pushing column to move toward the base, the pushing column pushes the moving column to move toward the shaping column and the positioning column, so as to stamp the workpiece in the horizontal direction.

[0017] In some embodiments, the upper mold is provided with clearance holes, which are used to avoid the shaping post, the positioning post and the moving post.

[0018] In some embodiments, the shaping column includes a first shaping column and a second shaping column, the positioning column includes a first positioning column and a second positioning column, the moving column includes a first moving column, a second moving column and a third moving column, and the pushing column includes a first pushing column, a second pushing column and a third pushing column;

[0019] The first shaping post and the second shaping post are respectively disposed on both sides of the second arc-shaped surface. The first positioning post and the second positioning post are respectively disposed on both sides of the first shaping post and the second shaping post. The second moving post is disposed on the second arc-shaped surface. The first moving post and the third moving post are respectively disposed on both sides of the second moving post. The first pushing post is configured to cooperate with the first moving post. The second pushing post is configured to cooperate with the second moving post. The third pushing post is configured to cooperate with the third moving post.

[0020] In some embodiments, the first movable column, the second movable column, and the third movable column are each provided with a first inclined surface, and the first pushing column, the second pushing column, and the second pushing column are each provided with a second inclined surface, the second inclined surface being configured to cooperate with the first inclined surface.

[0021] In some embodiments, the guide assembly includes a plurality of guide members and a plurality of elastic members, the plurality of guide members being respectively connected to the base, the upper plate being slidably connected to the plurality of guide members, the plurality of elastic members being respectively sleeved on the plurality of guide members, and the plurality of elastic members being respectively located between the base and the upper plate.

[0022] In some embodiments, the molding apparatus further includes a limiting component connected to the base and the upper plate, which is used to limit the movement distance of the upper plate.

[0023] In some embodiments, the limiting component includes a plurality of limiting members, some of which are connected to the side of the base facing the upper plate, and some of which are connected to the side of the upper plate facing the base.

[0024] In some embodiments, the molding apparatus further includes a pressure-applying member connected to the upper plate.

[0025] The forming apparatus of this application includes a base, a guide assembly, an upper plate, and a processing mechanism. The processing mechanism includes a lower mold, an upper mold, a lower mold pin assembly, and an upper mold pin assembly. The guide assembly is connected to the base, and the upper plate is movably connected to the guide assembly. The lower mold is mounted on the base, the lower mold pin assembly is mounted on the lower mold, the upper mold is mounted on the upper plate, and the upper mold pin assembly is mounted on the upper mold. When the upper plate moves the upper mold and the upper mold pin assembly toward the base, the upper mold can cooperate with the lower mold to perform stamping forming of the workpiece in the vertical direction; the upper mold pin assembly can cooperate with the lower mold pin assembly to perform stamping forming of the workpiece in the horizontal direction. Compared with the prior art, this application integrates the horizontal movement of 2D forming and the vertical movement of 3D forming, which greatly improves the efficiency of flat copper wire forming, eliminates the redundant 2D forming process of the intermediate "roof" part, saves production cycle time, improves production efficiency, and reduces production costs. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the structure of the workpiece to be processed provided in an embodiment of this application.

[0027] Figure 2 A perspective view of the molding apparatus provided in an embodiment of this application.

[0028] Figure 3 This is a schematic diagram of the processing mechanism provided in an embodiment of this application.

[0029] Figure 4 This is a schematic diagram of the structure of the lower mold provided in an embodiment of this application.

[0030] Figure 5 This is a structural schematic diagram of the lower mold and lower mold pin assembly provided in the embodiments of this application.

[0031] Figure 6 This is a structural schematic diagram of the upper mold and upper mold pin assembly provided in the embodiments of this application.

[0032] Figure 7 Another perspective view of the molding apparatus provided in the embodiments of this application.

[0033] Figure 8 This is an exploded perspective view of the molding apparatus provided in an embodiment of this application.

[0034] Attached image labels:

[0035] 1. Base; 2. Guide assembly; 21. Guide component; 22. Elastic component; 3. Upper plate; 4. Machining mechanism; 41. Lower mold; 411. First machining surface; 411a. First arc-shaped surface; 411b. Second arc-shaped surface; 411c. Third arc-shaped surface; 42. Upper mold; 421. Second machining surface; 422. Clearance hole; 43. Lower mold pin assembly; 430. First inclined surface; 431. First shaping post; 432. Second shaping post; 433. First positioning post; 43 4. Second positioning post; 435. First moving post; 436. Second moving post; 437. Third moving post; 44. Upper mold pin assembly; 440. Second inclined surface; 441. First pushing post; 442. Second pushing post; 443. Third pushing post; 5. Limiting assembly; 51. First limiting component; 52. Second limiting component; 53. Third limiting component; 54. Fourth limiting component; 55. Fifth limiting component; 56. Sixth limiting component; 6. Pressure applying component; 100. Flat copper wire hair clip. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0037] In the description of this application, unless otherwise expressly specified and limited, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance; unless otherwise specified or explained, the term "multiple" refers to two or more; the terms "connected," "fixed," etc., should be interpreted broadly. For example, "connected" can be a fixed connection, a detachable connection, an integral connection, or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0038] In the description of this specification, it should be understood that the directional terms such as "upper" and "lower" used in the embodiments of this application are used to describe the angles shown in the accompanying drawings and should not be construed as limiting the embodiments of this application. Furthermore, in the context, it should also be understood that when it is mentioned that an element is connected "upper" or "lower" to another element, it can be directly connected to the other element "upper" or "lower," or indirectly connected to the other element "upper" or "lower" through an intermediate element.

[0039] Currently, the main methods for achieving five-point forming of stator clips in flat copper wire motors are 2D five-point bending and 3D forming. Among these, 2D five-point bending can... Figure 1 The five points A1, A2, A3, A4, and A5 in the text refer to 3D molding. Figure 1 The deformation occurs in the Z-direction, while the production cycle time for 2D five-point bending is generally around 2.5 seconds. In related technologies, the 2D forming mold and the 3D forming mold can be designed as independent molds. During the flat copper wire forming process, the flat copper wire needs to be first 2D shaped horizontally, then removed, and then 2D five-point shaped. Finally, the 2D shaped hairpin is placed into the 3D mold, causing the 2D shaped hairpin to undergo plastic deformation again, ultimately obtaining a 3D shaped hairpin that meets the requirements. This method, which designs and develops the 2D and 3D molds separately, not only results in complex mechanisms and increased production costs, but also low hairpin forming efficiency. This is because 2D forming requires five bends, resulting in a large number of forming actions, leading to a long overall forming time and reduced efficiency. Furthermore, 2D forming requires two 2D three-point bending processes (…). Figure 1 After points A1, A2, and A3 are formed, the top two points are then processed again. Figure 1 The molding process involves forming points A4 and A5, which increases the mold structure and manufacturing costs.

[0040] Reference Figure 1 As shown, an embodiment of this application discloses a forming apparatus that can be applied to forming flat copper wire hair clips for motors. The forming apparatus includes a base 1, an upper plate 3, a guide assembly 2, a limiting assembly 5, a processing mechanism 4, and a pressure applying component 6. The guide assembly 2 is connected to the base 1, and the upper plate 3 is movably connected to the guide assembly 2, allowing the upper plate 3 to move along the guide assembly 2 in the vertical direction (…). Figure 2 The upper plate 3 moves along the Z-direction. The limiting component 5 is connected to the base 1 and the upper plate 3 respectively, and is used to limit the movement distance of the upper plate 3. The processing mechanism 4 is mounted on the base 1 and the upper plate 3, and is used to perform forming processing on the workpiece (which can be, for example, a flat copper wire hair clip). The pressure applying component 6 is connected to the side of the upper plate 3 facing away from the base 1, and is used to connect to an external press to apply pressure to the upper plate 3, allowing the upper plate 3 to move along the guide component 2 towards the base 1.

[0041] When processing the workpiece, the press can apply pressure to the upper plate 3 through the pressure applying component 6, causing the upper plate 3 to move along the guide component 2 toward the base 1. During the movement of the upper plate 3 toward the base 1, the processing mechanism 4 can perform forming processing on the workpiece. At the same time, during the movement of the upper plate 3, the movement distance of the upper plate 3 can be limited by the limiting component 5 to prevent the upper plate 3 from moving too much and causing the processing mechanism 4 to over-process the workpiece.

[0042] Reference Figure 3As shown, the processing mechanism 4 includes a lower mold 41, an upper mold 42, a lower mold pin assembly 43, and an upper mold pin assembly 44. The lower mold 41 is installed on the side of the base 1 facing the upper plate 3, and the lower mold pin assembly 43 is installed on the side of the lower mold 41 facing the upper plate 3. The upper mold 42 is installed on the side of the upper plate 3 facing the base 1, and the upper mold pin assembly 44 is installed on the side of the upper mold 42 facing the lower mold 41. When the upper plate 3 drives the upper mold 42 and the upper mold pin assembly 44 to move along the guide assembly 2 towards the base 1, the upper mold 42 can cooperate with the lower mold 41 to stamp the flat copper wire hair clip 100 in the vertical direction (3D forming), and the upper mold pin assembly 44 can cooperate with the lower mold pin assembly 43 to stamp the flat copper wire hair clip 100 in the horizontal direction (2D forming of points A4 and A5).

[0043] In this embodiment, the lower die pin assembly 43 includes a shaping pin, a positioning pin, and a moving pin, and the upper die pin assembly 44 includes a pushing pin. The shaping pin, positioning pin, and moving pin are respectively installed on the lower die 41, and the pushing pin is installed on the upper die 42. When the upper plate 3 drives the pushing pin to move toward the base 1, the pushing pin can push the moving pin to move toward the shaping pin and the positioning pin, so as to stamp and form the flat copper wire hair clip in the horizontal direction.

[0044] This application combines 2D and 3D molding at the top (roof) of the flat copper wire into a mold, utilizing the principle of cam molding and a well-designed motion stroke to achieve simultaneous 2D and 3D molding in a short time, thereby improving production efficiency.

[0045] Reference Figure 4 As shown, the lower mold 41 has a first processing surface 411 on the side facing the upper mold 42. The first processing surface 411 includes a first arc surface 411a, a second arc surface 411b and a third arc surface 411c. The first arc surface 411a and the third arc surface 411c are located on both sides of the second arc surface 411b, and the side of the second arc surface 411b closer to the third arc surface 411c is higher than the side of the second arc surface 411b closer to the first arc surface 411a.

[0046] Reference Figure 5As shown, exemplarily, the shaping column may include a first shaping column 431 and a second shaping column 432, the positioning column may include a first positioning column 433 and a second positioning column 434, and the moving column may include a first moving column 435, a second moving column 436, and a third moving column 437. The first shaping column 431 is disposed on the first arc-shaped surface 411a, the second shaping column 432 is disposed on the third arc-shaped surface 411c, and the first shaping column 431 and the second shaping column 432 are respectively located on both sides of the second arc-shaped surface 411b. The first positioning column 433 is disposed on the first arc-shaped surface 411a, the second positioning column 434 is disposed on the third arc-shaped surface 411c, and the first positioning column 433 and the second positioning column 434 are respectively located on both sides of the first shaping column 431 and the second shaping column 432. The second moving post 436 is located on the second arc-shaped surface 411b, the first moving post 435 is located on the first arc-shaped surface 411a, and the third moving post 437 is located on the third arc-shaped surface 411c. The first moving post 435 and the third moving post 437 are located on both sides of the second moving post 436. The position of the first moving post 435 corresponds to the position of the first positioning post 433, the position of the third moving post 437 corresponds to the position of the second positioning post 434, and the position of the second moving post 436 corresponds to the positions of the first shaping post 431 and the second shaping post 432.

[0047] Reference Figure 6 As shown, the upper mold 42 has a second processing surface 421 on the side facing the lower mold 41, and the shape of the second processing surface 421 is matched with the shape of the first processing surface 411. The push column may include a first push column 441, a second push column 442 and a third push column 443. The first push column 441 is matched with a first moving column 435, the second push column 442 is matched with a second moving column 436, and the third push column 443 is matched with a third moving column 437.

[0048] When the upper plate 3 moves the first pushing column 441, the second pushing column 442, and the third pushing column 443 toward the base 1, the first pushing column 441 can push the first moving column 435 toward the first positioning column 433, the second pushing column 442 can push the second moving column 436 toward the first shaping column 431 and the second shaping column 432, and the third pushing column 443 can push the third moving column 437 toward the second positioning column 434. This allows for the positioning of the first part of the workpiece by the first moving column 435 and the first positioning column 433, and the positioning of the second part of the workpiece by the third moving column 437 and the second positioning column 434. The second moving column 436, the first shaping column 431, and the second shaping column 432 are used to horizontally stamp and form the flat copper wire hair clip 100. Simultaneously, the first processing surface 411 and the second processing surface 421 cooperate to vertically stamp and form the flat copper wire hair clip 100.

[0049] To ensure better coordination between the pushing columns and the moving columns, the first moving column 435, the second moving column 436, and the third moving column 437 are each provided with a first inclined surface 430, and the first pushing column 441, the second pushing column 442, and the third pushing column 443 are each provided with a second inclined surface 440. The second inclined surface 440 and the first inclined surface 430 are configured to cooperate so that each pushing column can push each moving column to move. Simultaneously, the upper mold 42 is also provided with a clearance hole 422, which is used to avoid the shaping column, the positioning column, and the moving column.

[0050] Simultaneously refer to Figure 7 and Figure 8 As shown, the guide assembly 2 includes multiple guide members 21 and multiple elastic members 22. One end of each guide member 21 is connected to the base 1, and the other end of each guide member 21 is slidably connected to the upper plate 3. Multiple elastic members 22 are respectively sleeved on the guide members 21 and are located between the base 1 and the upper plate 3. The elastic members 22 can be used for resetting the upper plate 3, and can be configured as springs.

[0051] For example, four guide members 21 and four elastic members 22 are provided. The four guide members 21 are spaced apart, and one end of each guide member 21 is connected to the base 1. The other end of each guide member 21 is slidably connected to the upper plate 3. The four elastic members 22 are respectively sleeved on the four guide members 21. When pressure is applied to the upper plate 3, the upper plate 3 will move along the guide members 21 toward the base 1 and compress the elastic members 22. When pressure is no longer applied to the upper plate 3, the upper plate 3 will move away from the base 1 under the elastic force of the elastic members 22, that is, return to the initial position.

[0052] Continue to refer to Figure 7 and Figure 8As shown, the limiting assembly 5 includes multiple limiting members. Some of the limiting members are connected to the side of the base 1 facing the upper plate 3, and some of the limiting members are connected to the side of the upper plate 3 facing the base 1. Exemplarily, the multiple limiting members include a first limiting member 51, a second limiting member 52, a third limiting member 53, a fourth limiting member 54, a fifth limiting member 55, and a sixth limiting member 56. The first limiting member 51 and the second limiting member 52 are disposed at two corners of the base 1, the third limiting member 53 and the fourth limiting member 54 are disposed at two corners of the upper plate 3, and the third limiting member 53 cooperates with the first limiting member 51, and the fourth limiting member 54 cooperates with the second limiting member 52. The fifth limiting member 55 and the sixth limiting member 56 are disposed at the other two corners of the base 1. During the movement of the upper plate 3 along the guide member 21 toward the base 1, when the third limiting member 53 contacts the first limiting member 51, the fourth limiting member 54 contacts the second limiting member 52, and the upper plate 3 contacts the fifth limiting member 55 and the sixth limiting member 56, the upper plate 3 is limited and cannot continue to move downward. This embodiment utilizes the cam forming principle to integrate the horizontal movement of 2D forming and the vertical movement of 3D forming, greatly improving the efficiency of flat copper wire forming, eliminating the redundant 2D forming process of the intermediate "roof" part, and saving production cycle time.

[0053] The above description is merely a preferred embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A molding apparatus, characterized in that, The molding apparatus includes: Base; Guide assembly, the guide assembly being connected to the base; Upper plate, the upper plate being movably connected to the guide assembly; and The processing mechanism includes a lower mold, an upper mold, a lower mold pin assembly, and an upper mold pin assembly. The lower mold is mounted on the base, the lower mold pin assembly is mounted on the lower mold, the upper mold is mounted on the upper plate, and the upper mold pin assembly is mounted on the upper mold. When the upper plate moves the upper mold and the upper mold pin assembly toward the base, the upper mold can cooperate with the lower mold to stamp the workpiece in the vertical direction; the upper mold pin assembly can cooperate with the lower mold pin assembly to stamp the workpiece in the horizontal direction.

2. The molding apparatus according to claim 1, characterized in that, The lower mold has a first processing surface on the side facing the upper mold, and the upper mold has a second processing surface on the side facing the lower mold. The first processing surface includes a first arc-shaped surface, a second arc-shaped surface, and a third arc-shaped surface. The first arc-shaped surface and the third arc-shaped surface are respectively located on both sides of the second arc-shaped surface, and the side of the second arc-shaped surface closer to the third arc-shaped surface is higher than the side of the second arc-shaped surface closer to the first arc-shaped surface. The shape of the second processing surface is configured to match the shape of the first processing surface. When the upper plate moves the upper mold toward the base, the second processing surface cooperates with the first processing surface to stamp the workpiece in the vertical direction.

3. The molding apparatus according to claim 2, characterized in that, The lower mold pin assembly includes a shaping pin, a positioning pin, and a moving pin; the upper mold pin assembly includes a pushing pin; the shaping pin, the positioning pin, and the moving pin are respectively installed on the lower mold; and the pushing pin is installed on the upper mold. When the upper plate drives the pushing column to move toward the base, the pushing column pushes the moving column to move toward the shaping column and the positioning column, so as to stamp the workpiece in the horizontal direction.

4. The molding apparatus according to claim 3, characterized in that, The upper mold is provided with clearance holes, which are used to avoid the shaping column, the positioning column and the moving column.

5. The molding apparatus according to claim 3, characterized in that, The shaping column includes a first shaping column and a second shaping column; the positioning column includes a first positioning column and a second positioning column; the moving column includes a first moving column, a second moving column and a third moving column; and the pushing column includes a first pushing column, a second pushing column and a third pushing column. The first shaping post and the second shaping post are respectively disposed on both sides of the second arc-shaped surface. The first positioning post and the second positioning post are respectively disposed on both sides of the first shaping post and the second shaping post. The second moving post is disposed on the second arc-shaped surface. The first moving post and the third moving post are respectively disposed on both sides of the second moving post. The first pushing post is configured to cooperate with the first moving post. The second pushing post is configured to cooperate with the second moving post. The third pushing post is configured to cooperate with the third moving post.

6. The molding apparatus according to claim 5, characterized in that, The first moving column, the second moving column, and the third moving column are all provided with a first inclined surface, and the first pushing column, the second pushing column, and the second pushing column are all provided with a second inclined surface, which are configured to cooperate with the first inclined surface.

7. The molding apparatus according to claim 1, characterized in that, The guiding assembly includes multiple guide members and multiple elastic members. The multiple guide members are respectively connected to the base. The upper plate is slidably connected to the multiple guide members. The multiple elastic members are respectively sleeved on the multiple guide members and are respectively located between the base and the upper plate.

8. The molding apparatus according to claim 1, characterized in that, The molding device further includes a limiting component, which is connected to the base and the upper plate and is used to limit the movement distance of the upper plate.

9. The molding apparatus according to claim 8, characterized in that, The limiting assembly includes multiple limiting members, some of which are connected to the side of the base facing the upper plate, and some of which are connected to the side of the upper plate facing the base.

10. The molding apparatus according to any one of claims 1 to 9, characterized in that, The molding device also includes a pressure-applying component, which is connected to the upper plate.

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