An adjustable stator winding mold
By using the sliding groove and multi-positioning hole design of the adjustable stator winding die, the spacing between the die cores can be continuously adjusted, which solves the problem of poor versatility of traditional winding dies, improves production efficiency and reduces costs, and ensures the uniformity and stability of the winding process.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- 无锡欣吉力电机技术有限公司
- Filing Date
- 2025-08-26
- Publication Date
- 2026-07-31
AI Technical Summary
The fixed spacing of the core in traditional winding dies results in extremely poor versatility, requiring significant customization, high costs, and long response cycles, making it impossible to quickly adapt to the needs of multi-specification, small-batch stator production.
The adjustable stator winding die is adopted. Through the design of the slide groove and multiple positioning holes, the die core spacing is adjustable. Combined with the winding shaft driving all winding die units to rotate synchronously, the die core spacing can be continuously adjusted to adapt to various product specifications, reducing customization costs and inventory pressure.
It enables rapid and precise adjustment of the die core spacing, improves the versatility and production efficiency of the tooling, significantly reduces costs and inventory management complexity, shortens tooling preparation time, and ensures the uniformity and stability of the winding process.
Smart Images
Figure CN224583041U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of motor production equipment technology, specifically to an adjustable stator winding mold. Background Technology
[0002] In the field of motor manufacturing, the stator winding is a core component, and its forming quality directly affects the motor's performance. Stator windings are typically manufactured using a winding die, a tooling used to support and guide the enameled wire, forming a coil shape that meets design requirements. For a long time, the industry has generally adopted methods such as... Figure 1 and Figure 2 The traditional winding mold structure shown.
[0003] This traditional winding die consists of multiple structural units, each with a core component being a baffle and a first and second die core fixed to its two sides. Its key feature is that the baffle and the two die cores are typically formed as a rigid, integrated structure using integral casting or welding. While this design is structurally simple, it introduces a series of inherent problems that are difficult to overcome:
[0004] 1. Fixed die core spacing, extremely poor versatility: Due to the rigid connection between the die core and the baffle, the working distance between them is fixed and cannot be adjusted. This directly results in a winding die fixture only being suitable for a stator product of a specific thickness. Even slight changes in product specifications render the existing fixture completely ineffective.
[0005] 2. Heavy reliance on customization and a heavy burden on tooling management: To meet the production needs of stators of different specifications, manufacturers have to design and manufacture a dedicated winding die for each stator product of different thicknesses. With the diversification of product models, the number of dedicated tooling has expanded dramatically, resulting in a huge tooling inventory. This leads to complex warehousing management, frequent retrieval and use, and high maintenance costs.
[0006] 3. High costs for small-batch production: In today's market, which increasingly favors small-batch, multi-batch, and customized production, the drawbacks of the traditional model are particularly prominent. For a new stator specification with low demand, the cost of a single customized winding die may account for 30% or even higher of the total manufacturing cost of that batch of products.
[0007] 4. Long response time: When a new stator thickness specification needs to be produced, the process from design drawings to tooling manufacturing and acceptance often requires a waiting period of 2 to 3 weeks or even longer. This lengthy response time prevents the production line from quickly switching products, severely restricting the flexibility of the production line—that is, the ability to quickly adapt to product changes and efficiently organize multi-variety production. It becomes a bottleneck for improving production efficiency, shortening delivery cycles, and responding to rapid market changes.
[0008] Therefore, the motor manufacturing industry, especially enterprises involved in the production of stators in multiple specifications and small batches, urgently needs a new winding die solution that can overcome the aforementioned defects. The core objective of this solution should be to achieve rapid and reliable adjustment of the die core spacing, thereby significantly improving the versatility of tooling, greatly reducing customization costs and inventory pressure, and drastically shortening the tooling preparation time for new specifications of products. This utility model is proposed based on this urgent need. Utility Model Content
[0009] The purpose of this invention is to provide an adjustable stator winding mold to solve the problems mentioned in the background art.
[0010] To achieve the above objectives, this utility model provides the following technical solution: an adjustable stator winding die, comprising multiple winding die units and a winding shaft. Each winding die unit includes a baffle plate, the center of which is provided with a hollow portion for the winding shaft to pass through. The winding shaft passes through the hollow portion and is linked with the baffle plate. A first sliding groove and a second sliding groove are symmetrically arranged on both sides of the hollow portion on the baffle plate. The first sliding groove has a first set of positioning holes along its length direction, and the second sliding groove has a second set of positioning holes along its length direction. A first die core is detachably connected to the first set of positioning holes, and a second die core is detachably connected to the second set of positioning holes. The first die core can slide along the first sliding groove and is positioned / clamped / adjustably connected with the first set of positioning holes. The second die core can slide along the second sliding groove and is positioned / clamped / adjustably connected with the second set of positioning holes.
[0011] Preferably, the number of the first group of positioning holes and the second group of positioning holes is not less than 3, the first group of positioning holes is evenly distributed in the first slide groove, and the second group of positioning holes is evenly distributed in the second slide groove.
[0012] Preferably, the hollowed-out portion is a rectangular opening, and its inner wall is tightly fitted to the winding shaft.
[0013] Preferably, the width of both the first mold core and the second mold core is 80±5mm.
[0014] Preferably, the minimum adjustable distance between the first mold core and the second mold core is 50mm, and the maximum adjustable distance is 150mm.
[0015] Preferably, the hollowed-out portions of all winding mold units are fitted together on the same winding shaft, and the winding shaft can drive all winding mold units to rotate synchronously when it rotates.
[0016] Preferably, the first mold core is fixed by bolts passing through the selected positioning holes in the first set of positioning holes, and the second mold core is fixed by bolts passing through the selected positioning holes in the second set of positioning holes.
[0017] Compared with existing technologies, this utility model provides an adjustable stator winding die with the following advantages: Through the coordinated design of sliding grooves and multiple positioning holes, the die core spacing is continuously adjustable, covering a stator thickness range of 50mm to 150mm. This allows the same winding die to be adapted to various product specifications, completely eliminating the traditional customized tooling model and significantly reducing production costs and tooling management complexity. The die core is quickly assembled and disassembled with bolts, significantly shortening tooling adjustment time and improving production line response speed. The structure of the winding shaft driving all winding die units to rotate synchronously ensures uniform winding of the enameled wire and prevents loosening. The tight fit design between the baffle and the winding shaft further enhances overall stability. In summary, this invention achieves the core advantages of strong versatility, low cost, high efficiency, and easy operation. Attached Figure Description
[0018] Figure 1 This is a schematic diagram of an existing winding module unit structure;
[0019] Figure 2 This is a schematic diagram of an existing winding mold structure;
[0020] Figure 3 This is a schematic diagram of the winding module unit structure of this utility model;
[0021] Figure 4 for Figure 3 The diagram of the explosion;
[0022] Figure 5 This is a front view of the winding mold of this utility model;
[0023] Figure 6 This is an isometric view of the winding mold of this utility model.
[0024] Explanation of reference numerals in the attached drawings: 1. Winding mold unit; 2. Winding shaft; 3. Baffle; 31. Hollowed-out part; 4. First slide groove; 41. First set of positioning holes; 5. Second slide groove; 51. Second set of positioning holes; 6. First mold core; 7. Second mold core; 8. Bolt; 9. Existing winding mold unit; 10. Existing baffle; 11. Existing first mold core; 12. Existing second mold core; 13. Enamelled wire. Detailed Implementation
[0025] The technical solutions of the present utility model will now be described with reference to the accompanying drawings in the embodiments of the present utility model:
[0026] like Figure 1 and Figure 2As shown, the existing winding die includes multiple existing winding die units 9. Each existing winding die unit 9 includes an existing baffle 10 and existing first die core 11 and existing second die core 12 rigidly connected to it with a fixed spacing. This integrated structure leads to a critical drawback: the working spacing between the existing first die core 11 and existing second die core 12 cannot be adjusted. Therefore, for stator products of different thicknesses, a complete set of tooling must be customized for each specification. This not only causes a surge in tooling inventory and complex management, but also brings high customization costs and lengthy production cycles (usually 2-3 weeks), severely restricting production efficiency.
[0027] To overcome the shortcomings of the prior art, this utility model provides an adjustable stator winding mold, such as... Figure 3-6 As shown, the core of this winding die lies in the introduction of an adjustable-spacing die core design, fundamentally solving the problem of tooling versatility. Specifically, this adjustable stator winding die includes multiple winding die units 1 and a winding shaft 2. The multiple winding die units 1 are arranged at intervals along the length of the winding shaft 2, together forming the working skeleton for winding. The winding shaft 2 serves as the power input and rotation center axis of the entire winding die, its function being to transmit rotational torque and drive all winding die units 1 to rotate synchronously and coaxially. The winding die unit 1 includes a baffle 3, the center of which has a hollow portion 31 through which the winding shaft 2 passes. The hollow portions 31 of all winding die units 1 are collectively fitted onto the same winding shaft 2, and the rotation of the winding shaft 2 can drive all winding die units 1 to rotate synchronously. The hollow portion 31 is a rectangular opening, and its inner wall is tightly fitted to the winding shaft 2. The rectangular design ensures that there is no relative rotation (i.e., linkage) between the baffle 3 and the winding shaft 2, so that the rotation of the winding shaft 2 can directly and reliably drive the baffle 3 to rotate synchronously. This is the structural basis for ensuring the uniformity of winding.
[0028] The winding shaft 2 passes through the hollow section 31 and is linked with the baffle 3. The baffle 3 has a first sliding groove 4 and a second sliding groove 5 symmetrically arranged on both sides of the hollow section 31. The first sliding groove 4 and the second sliding groove 5 provide sliding guide tracks for the mold core, and their length direction determines the adjustable range of the mold core. The first sliding groove 4 has a first set of positioning holes 41 along its length direction, and the second sliding groove 5 has a second set of positioning holes 51 along its length direction. The number of positioning holes 41 and 51 in both sets is no less than three. The first set of positioning holes 41 is evenly distributed within the first sliding groove 4, and the second set of positioning holes 51 is evenly distributed within the second sliding groove 5. The first set of positioning holes 41 and the second set of positioning holes 51 provide discrete but fixed points covering the entire adjustment range, which are key structures for achieving precise positioning and reliable locking of the mold core.
[0029] The first set of positioning holes 41 detachably connects to the first mold core 6, and the second set of positioning holes 51 detachably connects to the second mold core 7, allowing for quick disassembly and installation, facilitating mold core replacement or maintenance. Both the first mold core 6 and the second mold core 7 have a width of 80±5mm, ensuring sufficient strength for forming the coil profile, while the ±5mm tolerance provides reasonable manufacturing and assembly tolerances. The first mold core 6 and the second mold core 7 are the core components that directly form the winding profile. The enameled wire 13 is wound in the space formed between the two opposing mold cores, and the spacing between them determines the final winding thickness.
[0030] The first mold core 6 can slide along the first slide groove 4 and is positioned / clamped / adjustably connected with the first set of positioning holes 41. The second mold core 7 can slide along the second slide groove 5 and is positioned / clamped / adjustably connected with the second set of positioning holes 51, thereby adjusting the distance between the first mold core 6 and the second mold core 7. The minimum adjustable distance between the first mold core 6 and the second mold core 7 is 50mm, and the maximum distance is 150mm. The first mold core 6 is fixed by bolts 8 passing through the selected positioning holes in the first set of positioning holes 41, and the second mold core 7 is fixed by bolts 8 passing through the selected positioning holes in the second set of positioning holes 51, firmly fixing the mold cores in the required positions on the baffle 3, ensuring the absolute stability of the mold cores during the winding process. By sliding the mold core along the slide and fixing it with different positioning holes, the center distance (i.e., working distance) between the first mold core 6 and the second mold core 7 can be adjusted within the range of 50mm to 150mm. This covers the thickness requirements of most common product specifications and is the core embodiment of this solution to enable one set of tooling to adapt to multiple product specifications, greatly improve the versatility of the equipment, and reduce tooling costs and inventory.
[0031] Core Innovation and Working Principle: The core of this utility model lies in its design combination of sliding grooves, multiple positioning holes, and detachable fixing bolts 8, replacing the traditional integrated structure. The mold core can slide freely within the sliding groove and be fixed by selecting different positioning holes, achieving continuous, precise, and lockable adjustment of the distance between the two mold cores, covering a wide range of stator thickness requirements. The baffles 3 of all winding mold units 1 are tightly fitted to the winding shaft 2 through their rectangular hollow parts 31, ensuring that when the winding shaft 2 rotates, it can drive all baffles 3 to rotate synchronously and coaxially. The mold cores fixed on the baffles 3 also rotate synchronously. The above-mentioned synchronous rotation structure, combined with the same mold core distance adjusted on all winding mold units 1, is the key to ensuring that the enameled wire 13 is evenly and tightly wound between multiple baffles 3, avoiding loosening or deformation of the coil.
[0032] Assembly and adjustment of the winding die (operation procedure):
[0033] 1. Install the winding shaft and baffles: Pass the winding shaft 2 sequentially through the rectangular cutout 31 at the center of the baffles 3 of all winding mold units 1. Adjust the axial position of each baffle 3 on the winding shaft 2 so that they are distributed according to the required working interval. Ensure that the inner wall of the cutout 31 of each baffle 3 is in close contact with the winding shaft 2 to achieve linkage.
[0034] 2. Installation and adjustment of mold core spacing: Place the first mold core 6 in the first groove 4 of the baffle 3, and place the second mold core 7 in the second groove 5 of the baffle 3. According to the thickness requirements of the target stator winding, slide the first mold core 6 and the second mold core 7 simultaneously along the groove direction to adjust the center distance between the two mold cores until the target value (within the range of 50mm-150mm) is reached.
[0035] 3. Fixing the mold core: When the first mold core 6 and the second mold core 7 slide to the target position, their mounting holes will align with a corresponding positioning hole on the slide groove. Pass the bolt 8 through the aligned positioning hole and the mounting hole on the mold core. Use a tool (such as a wrench) to tighten the bolt 8, firmly locking the mold core onto the baffle 3. This step must ensure that the bolt is fully tightened to prevent the mold core from shifting when subjected to tension during winding.
[0036] 4. Repeat adjustment: Repeat steps 2 and 3 for each winding die unit 1 to ensure that the center distance between the first die core 6 and the second die core 7 on all winding die units 1 is completely consistent. This is a necessary condition to ensure winding uniformity.
[0037] 5. Winding Operation: Install the assembled and adjusted winding die onto the winding equipment (automatic winding machine). Start the equipment to drive the winding shaft 2 to rotate. The winding shaft 2, through the hollowed-out portion 31 of the baffle 3 that fits tightly against it, drives all the baffles 3 and the die cores fixed thereon to rotate synchronously and coaxially. Guide the enameled wire 13 so that it is evenly wound around the space formed between the opposing first die core 6 and second die core 7 on all the winding die units 1. The synchronous rotation of all the winding die units 1 ensures the uniformity and tightness of the winding of the enameled wire 13 over the entire winding length.
[0038] Through the above structural design and operation process, this utility model has achieved significant technological progress:
[0039] Rapid assembly: When adapting to stators of different thicknesses, tooling adjustment can be completed simply by loosening bolt 8, sliding the first mold core 6 and the second mold core 7 to the new position, and then tightening bolt 8. This eliminates the time required for customization and waiting for new tooling (usually 2-3 weeks) in the traditional way, greatly improving the response speed and flexible production capacity of the production line.
[0040] High versatility and low cost: One set of tooling can cover stator thickness range of 50mm-150mm, completely solving the problem of one tooling for one specification, greatly reducing the customized manufacturing cost of tooling, warehousing management cost and inventory backlog risk.
[0041] High stability and reliability: The rigid connection between the mold core and the positioning holes on the baffle 3 via bolts 8 provides strong tensile strength and resistance to displacement. The tight linkage design between the winding shaft 2 and the hollowed-out part 31 of the baffle 3 ensures the reliability of power transmission and the strict synchronization of all units. The combination of these two points ensures the rigidity and stability of the overall structure during the winding process, effectively avoiding quality problems caused by loose winding, deformation, or asynchrony, and guaranteeing the accuracy and consistency of coil forming.
[0042] The above embodiments are merely some, not all, of the embodiments of this utility model. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without inventive effort are within the scope of protection of this utility model.
Claims
1. An adjustable stator winding die, characterized in that: The device includes multiple winding mold units (1) and winding shafts (2). Each winding mold unit (1) includes a baffle (3). The baffle (3) has a hollow portion (31) at its center for the winding shaft (2) to pass through. The winding shaft (2) passes through the hollow portion (31) and is linked with the baffle (3). The baffle (3) has a first sliding groove (4) and a second sliding groove (5) symmetrically arranged on both sides of the hollow portion (31). The first sliding groove (4) has a first set of positioning holes (41) along its length. The groove (5) has a second set of positioning holes (51) along its length. The first set of positioning holes (41) is detachably connected to the first mold core (6), and the second set of positioning holes (51) is detachably connected to the second mold core (7). The first mold core (6) can slide along the first slide groove (4) and is positioned / clamped / adjustably connected to the first set of positioning holes (41). The second mold core (7) can slide along the second slide groove (5) and is positioned / clamped / adjustably connected to the second set of positioning holes (51).
2. The adjustable stator winding die according to claim 1, characterized in that: The number of the first group of positioning holes (41) and the second group of positioning holes (51) is not less than 3. The first group of positioning holes (41) is evenly distributed in the first slide groove (4), and the second group of positioning holes (51) is evenly distributed in the second slide groove (5).
3. The adjustable stator winding mold according to claim 1, characterized in that... The hollow part (31) is a rectangular opening, and its inner wall is closely fitted with the winding shaft (2).
4. The adjustable stator winding die according to claim 1, characterized in that: The width of both the first mold core (6) and the second mold core (7) is 80±5mm.
5. The adjustable stator winding die according to claim 1, characterized in that: The minimum adjustable distance between the first mold core (6) and the second mold core (7) is 50 mm, and the maximum adjustable distance is 150 mm.
6. The adjustable stator winding die according to claim 1, characterized in that: The hollowed-out portions (31) of all winding mold units (1) are mounted on the same winding shaft (2), and the winding shaft (2) can drive all winding mold units (1) to rotate synchronously when it rotates.
7. The adjustable stator winding die according to claim 1, characterized in that: The first mold core (6) is fixed by bolts (8) passing through the selected positioning holes in the first set of positioning holes (41), and the second mold core (7) is fixed by bolts (8) passing through the selected positioning holes in the second set of positioning holes (51).