A stator shaping fixture

Abstract

This utility model belongs to the field of stator shaping technology, specifically relating to a stator shaping tooling, including a lower die, a slot wedge extrusion die on the lower die, an upper die above the slot wedge extrusion die, and a middle die on the outside of the slot wedge extrusion die. The winding is shaped by extruding inward through the middle die, and the upper die drives the slot wedge blade to extrude the slot wedge outward to shape the slot wedge, which facilitates slot wedge trimming. After trimming, no subsequent die expansion operation is required, reducing workload and improving production efficiency.

Description

Technical Field

[0001] This utility model belongs to the field of stator shaping technology, specifically relating to a stator shaping tooling. Background Technology

[0002] The stator core of an automotive alternator is one of its main components. It is assembled from the core, enameled wire, slot wedges, and slot insulation. The slot wedges and slot insulation are crucial insulating materials, preventing direct contact between the enameled wire and the core, which could lead to grounding issues. The slot wedges also protect the enameled wire from turning outwards. If the slot wedges crack or are not properly inserted, grounding problems can easily occur in the stator assembly. Currently, a separate process for expanding the mold and repairing the slot wedges is required in subsequent manufacturing steps, increasing workload and reducing production efficiency. Utility Model Content

[0003] To address the shortcomings of existing technologies, this utility model provides a stator shaping fixture. The winding is shaped by inward extrusion through the middle die, and the slot wedge is shaped by outward extrusion of the slot wedge blade inside the slot wedge extrusion die through the upper die. This facilitates slot wedge trimming and eliminates the need for subsequent die expansion operations after trimming. This solves the problem that currently, a separate die expansion and slot wedge trimming process is required in subsequent processes, which increases workload and reduces production efficiency.

[0004] To achieve the above objectives, this utility model is implemented through the following technical solution: a stator forming fixture, including a lower die, a slot wedge extrusion die provided on the lower die, an upper die provided above the slot wedge extrusion die, and a middle die provided on the outer side of the slot wedge extrusion die.

[0005] Preferably, the slot wedge extrusion die includes a lower baffle fixedly mounted on the lower die, an upper baffle above the lower baffle, a trapezoidal block fitted at the bottom of the upper baffle, and a plurality of mounting slots equidistantly arranged around the outer periphery of the upper baffle and the lower baffle, with slot wedge blades provided inside all mounting slots.

[0006] Preferably, one side of the slotted wedge blade is provided with a slope, and the inclined surface of the slope of the slotted wedge blade is slidably connected to the inclined surface of the trapezoidal block.

[0007] Preferably, the top of the trapezoidal block is provided with a fixing pin, the upper baffle is provided with a through hole for the fixing pin to pass through, and a circular boss is provided at the center of the upper baffle.

[0008] Preferably, the middle mold includes a left middle mold and a right middle mold. The inner side of both the left and right middle molds is provided with an annular groove for shaping the outer diameter of the winding, and the outer side of both the left and right middle molds is provided with a connecting groove for connecting external equipment.

[0009] Preferably, the upper mold includes a fixed plate, and an annular pressure plate is provided at the bottom of the fixed plate, with an avoidance groove provided on the inner side of the annular pressure plate.

[0010] Preferably, the lower mold includes a fixed base, a fixed block is provided on the top of the fixed base, a positioning groove is provided on the fixed block, and a positioning block matching the positioning groove is provided on the bottom of the lower baffle.

[0011] Preferably, the lower die, the slot wedge extrusion die, the upper die, and the middle die are all made of metal.

[0012] Compared with the prior art, the beneficial effects of this utility model are as follows: the upper die extrudes the slot wedge blade inside the slot wedge extrusion die to shape the winding, and the middle die extrudes inward, which is convenient for trimming. After trimming, there is no need for subsequent die expansion operation, which reduces the workload and improves production efficiency.

[0013] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description or may be learned by practice of the invention. Attached Figure Description

[0014] Figure 1 This is a three-dimensional structural diagram of a stator shaping fixture.

[0015] Figure 2 A three-dimensional structural breakdown of a stator shaping fixture Figure 1 .

[0016] Figure 3 A three-dimensional structural breakdown of a stator shaping fixture Figure 2 .

[0017] Figure 4 A three-dimensional structural breakdown of a stator shaping fixture Figure 3 .

[0018] Figure 5 This is a cross-sectional view of a stator shaping fixture.

[0019] Figure 6 An exploded view of the three-dimensional structure of a slot wedge extrusion die for a stator shaping tooling.

[0020] Figure 7 An exploded view of the three-dimensional structure of a slot wedge extrusion die for a stator shaping tooling.

[0021] In the diagram: 1. Lower die; 11. Fixed base; 12. Fixed block; 13. Positioning groove; 2. Slot wedge extrusion die; 21. Lower baffle; 211. Positioning block; 22. Upper baffle; 221. Through hole; 222. Circular boss; 23. Trapezoidal block; 231. Fixed pin; 24. Mounting groove; 25. Slot wedge blade; 251. Slope; 3. Upper die; 31. Fixed plate; 32. Annular pressure plate; 33. Clearance groove; 4. Middle die; 41. Left middle die; 42. Right middle die; 43. Annular groove; 44. Connecting groove. Detailed Implementation

[0022] The embodiments of this utility model will now be described in detail with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of this utility model. All other embodiments obtained by those skilled in the art without inventive effort are within the scope of protection of this utility model.

[0023] Combination Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, a stator forming fixture includes a lower die 1, a slot wedge extrusion die 2 is provided on the lower die 1, an upper die 3 is provided above the slot wedge extrusion die 2, and a middle die 4 is provided on the outer side of the slot wedge extrusion die 2.

[0024] This invention proposes a stator shaping fixture. The lower die 1 provides a stable base for the entire fixture's operation. The slot wedge extrusion die 2 is positioned above the lower die 1 and directly participates in the stator shaping operation, especially for slot wedge-related shaping work. The upper die 3 is located above the slot wedge extrusion die 2 and is positioned opposite to it. It cooperates with the slot wedge extrusion die 2 through vertical movement or the application of pressure to perform the stator shaping operation. The middle die 4 is positioned outside the slot wedge extrusion die 2, playing an auxiliary and cooperating role.

[0025] The forming die is placed on a matching hydraulic press. The upper die 3 is fixed to the upper pressure head, and the lower die 1 is fixed to the lower pressure head. The slot wedge extrusion die 2 is bolted to the lower die 1. During use, with the stator lead wire facing downwards, the lower die 6 is inserted into the slot wedge extrusion die 2 at the corresponding angle. The start button is pressed, and the upper die 3 presses the stator downwards, while the middle die 4 presses the stator inwards. The lower die 1 and the slot wedge extrusion die 2 rotate with the rotary cylinder for straightening and shaping. Simultaneously, the slot wedge extrusion die 2 extrudes the slot wedge, facilitating its removal later. The entire process, through the coordinated operation of the upper die 3, the slot wedge extrusion die 2, and the middle die 4, completes the stator shaping.

[0026] Combination Figure 3 , Figure 4 , Figure 6 and Figure 7 As shown, the slot wedge extrusion die 2 includes a lower baffle 21 fixedly installed on the lower die 1, an upper baffle 22 is provided above the lower baffle 21, a trapezoidal block 23 is sleeved on the bottom of the upper baffle 22, and a number of mounting slots 24 are equidistantly arranged around the outer periphery of the upper baffle 22 and the lower baffle 21, and slot wedge blades 25 are provided inside all mounting slots 24.

[0027] Specifically, the lower baffle 21 provides a stable mounting reference and bottom support for the entire slot wedge extrusion die 2, ensuring the stability of subsequent component installation. The upper baffle 22 is located above the lower baffle 21 and is positioned vertically corresponding to the lower baffle 21. The upper baffle 22 is an important component of the upper structure of the slot wedge extrusion die 2, and its bottom is fitted with a trapezoidal block 23, which plays a role in connecting and supporting other key components in the overall structure.

[0028] The trapezoidal block 23 is fitted onto the bottom of the upper baffle 22. The shape of the trapezoidal block 23, which is narrow at the top and wide at the bottom, helps to achieve specific mechanical transmission and shape shaping functions during the extrusion process, guiding the slot wedge material to be extruded and deformed according to the trapezoidal contour, thereby meeting the forming requirements of the stator slot wedge.

[0029] Several mounting slots 24 are equidistantly arranged around the outer periphery of the upper baffle 22 and the lower baffle 21. These mounting slots 24 are evenly distributed, providing mounting positions for the slot wedge blades 25, ensuring that the slot wedge blades 25 can be evenly stressed during the extrusion process and accurately cut and extrude the slot wedge material.

[0030] The slotted wedge insert 25 is installed inside all the mounting slots 24. The slotted wedge insert 25 can process the slotted wedge material during the extrusion process to form it into the shape and size required by the design.

[0031] First, the groove wedge material to be processed is placed in a suitable position, so that it is within the space enclosed by the upper baffle 22, the lower baffle 21, and the groove wedge blade 25. Since the lower baffle 21 is fixedly installed on the lower die 1, it provides a stable reference for the entire extrusion process, ensuring that the groove wedge material will not shift during the extrusion process.

[0032] When external pressure is applied to the upper baffle 22, the upper baffle 22 drives the trapezoidal block 23 fitted at its bottom to move downwards. The special shape of the trapezoidal block 23, during its downward movement, generates an inward compressive force on the surrounding slot wedge material, causing the slot wedge material to gradually deform according to the trapezoidal contour. Simultaneously, the slot wedge blades 25, equidistantly arranged around the outer periphery of the upper baffle 22 and the lower baffle 21, begin to function. Since the slot wedge blades 25 are installed within the mounting groove 24, they compress the slot wedge material outwards as the upper baffle 22 moves downwards. The equidistant arrangement of the mounting groove 24 ensures that the slot wedge blades 25 can uniformly compress the slot wedge material outwards during the compression process, ensuring that all parts of the slot wedge material are subjected to the same pressure, thereby forming a regularly shaped and precisely sized slot wedge. Through the above compression and cutting process, the slot wedge material, under the combined action of the trapezoidal block 23 and the slot wedge blades 25, gradually takes shape into a stator slot wedge that meets the design requirements. Once the extrusion action is complete, the upper baffle 22 stops moving downwards. At this point, the stator slot wedge has been formed, and the processed stator can be removed, completing one slot wedge extrusion forming operation.

[0033] Combination Figure 3 , Figure 4 , Figure 6 and Figure 7 As shown, a ramp 251 is provided on one side of the slotted wedge blade 25, and the inclined surface of the ramp 251 of the slotted wedge blade 25 is slidably connected to the inclined surface of the trapezoidal block 23.

[0034] Specifically, a ramp 251 is provided on one side of the slotted wedge blade 25. This ramp 251 has a specific inclination angle and shape, and is an important structural feature for the slotted wedge blade 25 to cooperate with the trapezoidal block 23. The trapezoidal block 23 is fitted onto the bottom of the upper baffle 22 and has an inclined surface. This inclined surface corresponds to the inclined surface of the ramp 251 on the slotted wedge blade 25. The two are combined together by a sliding connection and jointly participate in the extrusion forming process of the slotted wedge.

[0035] Before the extrusion operation begins, the slotted wedge blade 25 is in its initial position, with the inclined surface of its ramp 251 in contact with the inclined surface of the trapezoidal block 23. However, since there is no external pressure, the two are in a relatively static sliding connection preparatory state, and the slotted wedge material has not yet been subjected to significant extrusion.

[0036] When external pressure (such as the downward pressure applied by the upper mold 3) acts on the upper baffle 22, the upper baffle 22 drives the trapezoidal block 23 to move downward. Since the trapezoidal block 23 has an inclined surface and is slidably connected to the inclined surface of the slope 251 of the slot wedge blade 25, during the downward movement of the trapezoidal block 23, its inclined surface applies a component force along the inclined surface direction to the slope 251 of the slot wedge blade 25. This component force causes the slot wedge blade 25 to move closer to the slot wedge material. As the trapezoidal block 23 continues to move downward, the slot wedge blade 25 gradually cuts into the slot wedge material under the action of the component force. Simultaneously, because the two are slidably connected, the slot wedge blade 25 can maintain a relatively stable trajectory during movement, ensuring uniform extrusion of the slot wedge material.

[0037] As the trapezoidal block 23 moves downwards, the slot wedge blade 25 continuously applies pressure to the slot wedge material. Under the action of the slot wedge blade 25, the slot wedge material is gradually compressed into the desired shape and size. The inclined surface design of the trapezoidal block 23 allows the compression force of the slot wedge blade 25 on the slot wedge material during its downward movement to be precisely controlled according to the moving distance and inclination angle of the trapezoidal block 23, thereby ensuring the forming quality of the stator slot wedge. When the trapezoidal block 23 moves to the predetermined position and completes the compression forming of the slot wedge material, the external pressure is stopped. At this time, the slot wedge blade 25 also stops compressing the slot wedge material, the stator slot wedge forming is complete, and the processed stator can be removed.

[0038] Combination Figure 4 , Figure 5 , Figure 6 and Figure 7 As shown, a fixing pin 231 is provided on the top of the trapezoidal block 23, and a through hole 221 is provided on the upper baffle 22 for the fixing pin 231 to pass through. A circular boss 222 is provided at the center of the upper baffle 22.

[0039] Specifically, the fixing pin 231 is perpendicular to the top surface of the trapezoidal block 23 and is an important structure for establishing the connection between the trapezoidal block 23 and the upper baffle 22. The upper baffle 22 has a through hole 221 for the fixing pin 231 to pass through. The position of the through hole 221 corresponds to the position of the fixing pin 231 on the top of the trapezoidal block 23, and its diameter is matched to the diameter of the fixing pin 231, ensuring that the fixing pin 231 can pass through smoothly, thus achieving the initial positioning and connection between the trapezoidal block 23 and the upper baffle 22.

[0040] The circular boss 222 is located at the center of the upper baffle 22. The circular boss 222 protrudes from the surface of the upper baffle 22 and has a certain height and diameter, which has an important impact on the overall performance and forming effect of the slot wedge extrusion die 2.

[0041] When assembling the slotted wedge extrusion die 2, the trapezoidal block 23 is placed at the corresponding position on the upper baffle 22, so that the fixing pin 231 at the top of the trapezoidal block 23 passes through the through hole 221 on the upper baffle 22. The engagement of the fixing pin 231 and the through hole 221 determines the position of the trapezoidal block 23 on the upper baffle 22, prevents the trapezoidal block 23 from shifting in the horizontal direction, and ensures the stability and accuracy of the connection between the two.

[0042] The circular boss 222 at the center of the upper baffle 22 serves as an auxiliary positioning feature during installation. When assembling the upper baffle 22, the circular boss 222 acts as a reference point, ensuring the accurate positioning of the upper baffle 22 within the entire slot wedge extrusion die 2, providing a good foundation for subsequent extrusion molding operations. When external pressure (such as the pressure applied by the upper die 3) is applied to the upper baffle 22, the upper baffle 22 will move the trapezoidal block 23 downwards together. Because the trapezoidal block 23 is firmly connected to the upper baffle 22 via the fixing pin 231 and the through hole 221, the two can maintain synchronous movement during downward movement, preventing relative sliding or misalignment.

[0043] As the trapezoidal block 23 moves downward, its inclined surface slides relative to the slope 251 of the slot wedge blade 25, thereby converting the pressure transmitted from the upper baffle 22 into extrusion force on the slot wedge material, gradually shaping the material. The circular boss 222 at the center of the upper baffle 22 may exert a certain effect on the center of the slot wedge material during extrusion. Throughout the extrusion process, the connection between the fixing pin 231 and the through hole 221 ensures the connection strength between the trapezoidal block 23 and the upper baffle 22, withstands the large pressure and friction generated during extrusion, and ensures that the trapezoidal block 23 will not loosen or fall off due to force, thus ensuring the stable and continuous operation of the slot wedge extrusion die 2. The circular boss 222 is always located at the center of the upper baffle 22, providing a stable central reference for the entire extrusion process, helping to maintain the balance and stability of the slot wedge extrusion die 2 during operation, and reducing forming errors caused by vibration or offset.

[0044] Combination Figure 2 , Figure 3 , Figure 4 and Figure 5 As shown, the middle mold 4 includes a left middle mold 41 and a right middle mold 42. The inner sides of the left middle mold 41 and the right middle mold 42 are provided with annular grooves 43 for shaping the outer diameter of the winding, and the outer sides of the left middle mold 41 and the right middle mold 42 are provided with connecting grooves 44 for connecting external devices.

[0045] Specifically, the left middle mold 41 and the right middle mold 42 are roughly symmetrical in shape, and together they form the main frame of the middle mold 4. This split design facilitates installation, disassembly, and operation of the stator windings, and can better adapt to the stator shaping needs of different sizes and shapes.

[0046] Annular grooves 43 are provided on the inner sides of both the left middle mold 41 and the right middle mold 42. The shape of the annular grooves 43 matches the outer diameter of the stator winding, and their function is to shape the outer diameter of the stator winding. Through the restriction and compression of the annular grooves 43, the shape of the winding can be made more regular and the dimensions more accurate, thereby improving the electrical performance and mechanical stability of the stator.

[0047] Both the left middle mold 41 and the right middle mold 42 have connecting grooves 44 on their outer sides. The connecting grooves 44 are used to connect external equipment, such as drive devices, fixed brackets, etc. Through the connecting grooves 44, the middle mold 4 can be reliably connected to other equipment, realizing the motion control and positioning of the middle mold 4 and the stable installation of the overall tooling.

[0048] Combination Figure 2 , Figure 3 , Figure 4 and Figure 5As shown, the upper mold 3 includes a fixing plate 31, and an annular pressure plate 32 is provided at the bottom of the fixing plate 31. An avoidance groove 33 is provided on the inner side of the annular pressure plate 32.

[0049] Specifically, the annular pressure plate 32 is located at the bottom of the fixed plate 31 and is fixedly connected to the fixed plate 31, forming an integral structure. The annular pressure plate 32 is annular, and its outer and inner diameters are designed according to the specific application scenario and the size of the workpiece being processed (such as a stator). A clearance groove 33 is formed on the inner side of the annular pressure plate 32. The shape and size of the clearance groove 33 are determined based on the parts on the workpiece that need to be avoided (such as winding leads, protruding structures, etc. on the stator), and its function is to prevent the annular pressure plate 32 from interfering with these parts during the downward pressing of the upper die 3.

[0050] Combination Figure 2 , Figure 3 , Figure 4 and Figure 5 As shown, the lower mold 1 includes a fixed base 11, a fixed block 12 is provided on the top of the fixed base 11, a positioning groove 13 is provided on the fixed block 12, and a positioning block 211 matching the positioning groove 13 is provided on the bottom of the lower baffle 21.

[0051] Specifically, the fixed base 11 is installed on the worktable and fixed to the worktable by bolts or other connecting parts to ensure that it will not move or shake during processing. The fixed block 12 is set on top of the fixed base 11 and is fixedly connected to the fixed base 11 by means of welding, bolt connection, etc. The shape and size of the fixed block 12 are determined according to specific design requirements, and its function is to provide positioning and support for the lower baffle 21.

[0052] The positioning groove 13 is formed on the fixing block 12, and its shape and size match the positioning block 211 at the bottom of the lower baffle 21. The depth, width and length of the positioning groove 13 need to be precisely machined to ensure that the positioning block 211 can be accurately accommodated, so as to achieve precise positioning of the lower baffle 21 on the fixing block 12.

[0053] The lower baffle 21 is a component in the mold that cooperates with the upper mold 3, middle mold 4, etc., and participates in the processing of workpieces such as the stator. A positioning block 211 is provided at the bottom of the lower baffle 21. The shape and size of the positioning block 211 correspond to the positioning groove 13 and can be inserted into the positioning groove 13 to realize the positioning connection between the lower baffle 21 and the fixing block 12.

[0054] Combination Figure 1 , Figure 2 , Figure 3 and Figure 4As shown, the lower die 1, the slot wedge extrusion die 2, the upper die 3, and the middle die 4 are all made of metal.

[0055] Specifically, the lower die 1, the slot wedge extrusion die 2, the upper die 3, and the middle die 4 are all made of metal. Metal possesses properties such as high strength, high hardness, good wear resistance, and thermal conductivity. These properties enable the dies to withstand significant pressure, high temperatures, and friction during operation, ensuring processing accuracy and quality. Due to the excellent thermal conductivity of metal, the heat generated during processing can be dissipated quickly. Cooling channels can be incorporated into the dies, allowing cooling media (such as water or oil) to accelerate the cooling process, enabling the workpiece to solidify rapidly and improving production efficiency.

[0056] The above embodiments only illustrate one or more implementations of this utility model, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of this utility model. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the appended claims.

Claims

1. A stator shaping fixture, comprising a lower mold (1), characterized in that, A slotted wedge extrusion die (2) is provided on the lower die (1), an upper die (3) is provided above the slotted wedge extrusion die (2), and a middle die (4) is provided on the outside of the slotted wedge extrusion die (2). The slot wedge extrusion die (2) includes a lower baffle (21) fixedly installed on the lower die (1), an upper baffle (22) is provided above the lower baffle (21), a trapezoidal block (23) is sleeved on the bottom of the upper baffle (22), and a number of mounting slots (24) are equidistantly arranged around the outer periphery of the upper baffle (22) and the lower baffle (21), and slot wedge blades (25) are provided inside all mounting slots (24).

2. The stator shaping fixture according to claim 1, characterized in that, A ramp (251) is provided on one side of the slotted wedge blade (25), and the inclined surface of the ramp (251) of the slotted wedge blade (25) is slidably connected to the inclined surface of the trapezoidal block (23).

3. The stator shaping fixture according to claim 2, characterized in that, The top of the trapezoidal block (23) is provided with a fixing pin (231), and the upper baffle (22) is provided with a through hole (221) for the fixing pin (231) to pass through. A circular boss (222) is provided at the center of the upper baffle (22).

4. The stator shaping fixture according to claim 3, characterized in that, The middle mold (4) includes a left middle mold (41) and a right middle mold (42). The inner sides of the left middle mold (41) and the right middle mold (42) are provided with annular grooves (43) for shaping the outer diameter of the winding, and the outer sides of the left middle mold (41) and the right middle mold (42) are provided with connecting grooves (44) for connecting external devices.

5. A stator shaping fixture according to claim 4, characterized in that, The upper mold (3) includes a fixing plate (31), and an annular pressure plate (32) is provided at the bottom of the fixing plate (31). An avoidance groove (33) is provided on the inner side of the annular pressure plate (32).

6. A stator shaping fixture according to claim 5, characterized in that, The lower mold (1) includes a fixed base (11), a fixed block (12) is provided on the top of the fixed base (11), a positioning groove (13) is provided on the fixed block (12), and a positioning block (211) matching the positioning groove (13) is provided at the bottom of the lower baffle (21).

7. A stator shaping fixture according to claim 6, characterized in that, The lower die (1), the slot wedge extrusion die (2), the upper die (3) and the middle die (4) are all made of metal.

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