High slot fill rate inner winding wire mechanism

Abstract

The utility model discloses a kind of high groove fullness rate inner winding flat cable mechanism, including supporting assembly, flat cable module and limit module, flat cable module is located at the inner side wall of supporting assembly, limit module is located at the inner side wall of flat cable module, it is convenient to limit flat cable module, flat cable module includes flat cable block body, upper flat cable block and secondary flat cable block body, upper flat cable block is located at one end of flat cable block body, secondary flat cable block body is located at one end of flat cable block body, by optimizing the collaborative design of flat cable module and limit module, the precise filling of wire in stator slot is realized, effectively reduce wire gap, reduce copper loss, to improve motor efficiency and power density;Meanwhile, high filling rate design improves heat dissipation channel, prolongs motor service life, by the combination of modular flat cable structure (flat cable block body, upper / secondary flat cable block, lower flat cable block etc.) and adjustable limit component, it can be self-adapting multilayer winding or the space variation of special-shaped slot, avoid wire accumulation uneven or slot overflow.

Description

Technical Field

[0001] This utility model relates to the technical field of winding machine equipment, specifically a high slot fill factor internal winding mechanism. Background Technology

[0002] With the continuous development of motor technology, the requirements for motor power density, efficiency, and reliability are increasing. The slot fill factor (i.e., the conductor filling rate in the stator slots) of the motor stator winding has become a key factor affecting motor performance. High slot fill factor design can effectively reduce the gap between conductors, reduce copper losses, improve motor efficiency and output power density, and optimize heat dissipation performance, meeting the urgent needs of new energy vehicles, industrial drives, aerospace and other fields for high-efficiency and compact motors.

[0003] Conventional external winding or manual winding methods make it difficult to accurately control the density of the wire arrangement in the slot, which can easily lead to loose, misaligned, or crossed wires. This results in the actual slot fill factor being far lower than the theoretical value, and there is also a risk of local overheating. Existing automated winding equipment often uses fixed trajectories or simple tension control for its wire arrangement mechanism, which cannot dynamically adapt to changes in the slot space. Especially in multi-layer winding or irregularly shaped slot structures, problems such as uneven wire accumulation and slot overflow are likely to occur. To solve this problem, the inventors have proposed a high slot fill factor internal winding mechanism. Summary of the Invention

[0004] To address the shortcomings of the aforementioned technologies, this utility model provides a high slot fill factor internal winding cable arrangement mechanism.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a high slot full rate inner winding cable laying mechanism, comprising a support component, a cable laying module, and a limiting module. The cable laying module is disposed on the inner side wall of the support component, and the limiting module is disposed on the inner side wall of the cable laying module to facilitate limiting the cable laying module. The cable laying module includes a cable laying block body, an upper cable laying block, and a secondary cable laying block body. The upper cable laying block is disposed at one end of the cable laying block body, and the secondary cable laying block body is disposed at one end of the cable laying block body.

[0006] As a further explanation, it also includes a wiring mold and a hanging post. The wiring mold is located on the inner side wall of the limiting module, and the hanging post is located on the upper surface of the wiring mold. There are multiple hanging posts arranged at intervals.

[0007] As a further explanation, it also includes a lower wiring block and a lower auxiliary wiring block, wherein the lower wiring block is disposed on the inner side wall of the support assembly, and the lower auxiliary wiring block is disposed at one end of the lower wiring block.

[0008] As further explained, the limiting module includes a fixing block and a fixing clamp, the fixing clamp being disposed at one end of the support assembly, and the fixing block being disposed on the inner side wall of the fixing clamp.

[0009] As further explained, the fixing block extends outward to provide a mounting seat, which is located on the upper surface of the support component. The mounting seat extends inward to provide a limiting groove, which is located on the inner sidewall of the mounting seat to facilitate limiting the fixing block. The wiring mold is located on the inner sidewall of the mounting seat.

[0010] As a further explanation, the mounting base extends outward and is provided with a limiting block, which is located on the inner sidewall of the mounting base.

[0011] As further explained, the support assembly includes a support, which is disposed on the inner sidewall of the fixing clamp.

[0012] As further explained, the support extends outward to form a support frame, which is located on the upper surface of the support. The lower cable block is located on the inner side wall of the support frame, and the mounting base is located on the upper surface of the support frame.

[0013] In summary, this utility model has the following beneficial effects: This utility model provides a high slot fill rate internal winding mechanism. Through optimized collaborative design of the winding module and the limiting module, it achieves precise filling of the conductors in the stator slots, effectively reducing conductor gaps and copper losses, thereby improving motor efficiency and power density. Simultaneously, the high fill rate design improves heat dissipation channels and extends motor lifespan. The combination of a modular winding structure (winding block body, upper / sub-winding block, lower winding block, etc.) and adjustable limiting components (fixed block, mounting base limiting slot) allows for adaptive adaptation to spatial changes in multi-layer winding or irregularly shaped slots, preventing uneven conductor accumulation or slot overflow, and ensuring a stable and controllable winding process. Attached Figure Description

[0014] Figure 1 This is a three-dimensional structural diagram of a high slot fill factor internal winding cable arrangement mechanism according to the present invention.

[0015] Figure 2 This is a schematic diagram of the structure of a high slot fill factor internal winding cable arrangement mechanism according to the present invention;

[0016] Figure 3 This is a schematic diagram of the limiting mold structure of a high slot full rate inner winding wire laying mechanism according to this utility model;

[0017] Figure 4 This is a schematic diagram of the wiring module structure of a high slot fill factor internal winding wiring mechanism according to this utility model;

[0018] Figure 5This is a schematic diagram of the wiring module structure of a high slot fill factor internal winding wiring mechanism according to this utility model. Detailed Implementation

[0019] 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.

[0020] like Figure 1-5 As shown, this utility model discloses a high slot full rate inner winding cable laying mechanism, including a support component, a cable laying module, and a limiting module. The cable laying module is disposed on the inner side wall of the support component, and the limiting module is disposed on the inner side wall of the cable laying module to facilitate limiting the cable laying module. The cable laying module includes a cable laying block body 21, an upper cable laying block 22, and a secondary cable laying block body 23. The upper cable laying block 22 is disposed at one end of the cable laying block body 21, and the secondary cable laying block body 23 is disposed at one end of the cable laying block body 21.

[0021] Specifically, the cable routing block body 21 serves as the basic structure of the cable routing module, with an upper cable routing block 22 at one end and a secondary cable routing block body 23 at the other end. During the cable routing process, the upper cable routing block 22 and the secondary cable routing block body 23 work together to initially guide and arrange the wires, ensuring that the wires can enter the stator slots according to the predetermined path.

[0022] It also includes a wiring mold 26 and a hanging post 27. The wiring mold 26 is located on the inner side wall of the limiting module, and the hanging post 27 is located on the upper surface of the wiring mold. There are multiple hanging posts 27 arranged at intervals.

[0023] Specifically, before the wiring begins, the conductors can be pre-hanging on the hanging posts 27. The hanging posts 27 are used to initially organize and position the conductors, facilitating the smooth progress of subsequent wiring operations. During the wiring process, the hanging posts 27 also play a certain role in tension adjustment, ensuring that the conductors maintain appropriate tension when entering the wiring module and stator slots, preventing the conductors from becoming loose or overstretched.

[0024] It also includes a lower wiring block 24 and a lower auxiliary wiring block 25. The lower wiring block 24 is located on the inner side wall of the support assembly, and the lower auxiliary wiring block 25 is located at one end of the lower wiring block 24.

[0025] Specifically, at the same time, a lower cable tray 24 is provided on the support frame 12 of the support component. A lower auxiliary cable tray 25 is provided at one end of the lower cable tray 24. The lower cable tray 24 and the upper cable tray 22 cooperate with each other to clamp and guide the wires from both the upper and lower directions, thereby further controlling the arrangement density of the wires in the slot.

[0026] The limiting module includes a fixing block 301 and a fixing clamp 302. The fixing clamp 302 is located at one end of the support component. The fixing block 301 is located on the inner side wall of the fixing clamp 302. The fixing block 301 extends outward to provide a mounting seat 310, which is located on the upper surface of the support component. The mounting seat 310 extends inward to provide a limiting groove 311, which is located on the inner side wall of the mounting seat 310 to facilitate limiting the fixing block 301. The wiring mold 26 is located on the inner side wall of the mounting seat 310. The mounting seat 310 extends outward to provide a limiting block 312, which is located on the inner side wall of the mounting seat 310.

[0027] Specifically, the fixing block 301 is disposed on the inner wall of the fixing clamp 302. The mounting base 310 extending outward from the fixing block 301 is located on the upper surface of the support assembly (support frame 12). The mounting base 310 extends inward and has a limiting groove 311, which is used to precisely limit the fixing block 301, ensuring that the fixing block 301 maintains a stable position during the operation of the mechanism. Simultaneously, the limiting block 312 extending outward from the mounting base 310 further enhances the stability of the structure, preventing component displacement due to force during the wiring process. Furthermore, the wiring mold 26 is disposed on the inner wall of the mounting base 310. Through the positioning effect of the limiting module on the mounting base 310, the wiring mold 26 is precisely positioned, providing accurate mold guidance for subsequent wiring operations.

[0028] The support assembly includes a support 11, which is located on the inner wall of the fixing clamp 302. A support frame 12 extends outward from the support 11 and is located on the upper surface of the support 11. The lower cable block 24 is located on the inner wall of the support frame 12, and the mounting base 310 is located on the upper surface of the support frame 12.

[0029] Specifically, the support 11 of the support component serves as the installation foundation for the entire mechanism, providing a stable support platform for other components. A support frame 12 extends outward from the support 11, located on the upper surface of the support 11. The support frame 12 supports and positions some of the wiring components, providing space and structural support for wiring operations.

[0030] By optimizing the collaborative design of the wiring module and the limiting module, precise filling of the conductors in the stator slots is achieved, effectively reducing conductor gaps and copper losses, thereby improving motor efficiency and power density. At the same time, the high filling rate design improves the heat dissipation channel and extends the service life of the motor. Through the combination of modular wiring structure (wiring block body 21, upper / sub wiring block, lower wiring block 24, etc.) and adjustable limiting components (fixed block 301, mounting base 310 limiting slot 311), it can adapt to the spatial changes of multi-layer winding or irregular slots, avoid uneven conductor accumulation or slot overflow, and ensure that the winding process is stable and controllable.

[0031] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0032] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A high-slot full-rate internal winding mechanism, characterized in that: Including support components; A cabling module, wherein the cabling module is disposed on the inner sidewall of the support assembly; A limiting module is provided on the inner sidewall of the ribbon cable module to facilitate limiting the ribbon cable module; The wiring module includes a wiring block body, an upper wiring block, and a secondary wiring block body. The upper wiring block is located at one end of the wiring block body, and the secondary wiring block body is located at one end of the wiring block body.

2. The high slot fill factor internal winding mechanism according to claim 1, characterized in that: It also includes a wiring mold and wire hanging posts. The wiring mold is located on the inner side wall of the limiting module, and the wire hanging posts are located on the upper surface of the wiring mold. There are multiple wire hanging posts arranged at intervals.

3. The high slot fill factor internal winding mechanism according to claim 2, characterized in that: It also includes a lower wiring block and a lower auxiliary wiring block, wherein the lower wiring block is disposed on the inner side wall of the support assembly, and the lower auxiliary wiring block is disposed at one end of the lower wiring block.

4. The high slot fill factor internal winding mechanism according to claim 3, characterized in that: The limiting module includes a fixing block and a fixing clamp. The fixing clamp is located at one end of the support assembly, and the fixing block is located on the inner side wall of the fixing clamp.

5. The high slot fill factor internal winding mechanism according to claim 4, characterized in that: The fixing block extends outward to provide a mounting seat, which is located on the upper surface of the support component. The mounting seat extends inward to provide a limiting groove, which is located on the inner side wall of the mounting seat to facilitate limiting the fixing block. The wiring mold is located on the inner side wall of the mounting seat.

6. The high slot fill factor internal winding mechanism according to claim 5, characterized in that: The mounting base extends outward and is provided with a limiting block, which is located on the inner side wall of the mounting base.

7. A high slot fill factor internal winding mechanism according to claim 6, characterized in that: The support assembly includes a support, which is disposed on the inner sidewall of the fixing clamp.

8. The high slot fill factor internal winding mechanism according to claim 7, characterized in that: The support extends outward to form a support frame, which is located on the upper surface of the support. The lower cable block is located on the inner side wall of the support frame, and the mounting base is located on the upper surface of the support frame.

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