Coil end former for round wire, round wire motor, and vehicle

Abstract

A coil end former for round wire, a round wire motor and a vehicle, the coil end former comprising a blind angle coil pushing mechanism and a supporting mechanism, the blind angle coil pushing mechanism being arranged at a side of the round wire coil close to the center of the stator. The blind angle coil pushing mechanism comprises a diameter expanding component and at least one inner mold, the at least one inner mold being arranged at a side of the diameter expanding component away from the center of the stator. The diameter expanding component is configured to move along the radial direction of the stator to drive the at least one inner mold to move towards the round wire coil. The supporting mechanism is arranged at a radial side of the round wire coil away from the center of the stator. The supporting mechanism comprises an outer mold, the outer mold cooperating with the inner mold to shape the round wire coil by compressing the round wire coil.

Description

Technical Field

[0001] This application relates to the field of motor technology, and more particularly to a coil end forming device for round wire, a round wire motor, and a vehicle. Background Technology

[0002] Currently, the performance requirements for generators and drive motors in electric vehicle power systems are becoming increasingly stringent, leading to a rise in the use of high copper fill factor flat wire motors. Recently, even inexpensive round wire motors have been able to achieve performance close to that of flat wire motors.

[0003] For circular wire motors, unnecessary coil length at the coil ends must be shortened as much as possible to reduce energy loss.

[0004] For circular wire motors, the three-phase coils are typically inserted into the stator slots in three stages, one phase at a time. Internal and top spaces are reserved in the stator slots to allow for the insertion of the next phase coil. The internal space is used to embed the coil, and the top space is used to set the connecting wires at the coil ends. After each phase coil is inserted, the ends of the inserted coil are shaped to facilitate the insertion of the next phase coil.

[0005] Previously, existing technologies simply used thin flat panels (such as...) Figure 1A The thin flat push rod 10 is inserted into the stator slot where the next phase coil will be inserted, and it spreads outward radially along the stator to cover the inserted coil on the stator slot (see reference). Figure 1A-1B However, when using this thin flat push rod to shape the end of the inserted coil, there are many drawbacks, such as the coil being stretched and damaged, and significant deviations in the shape and path of the connecting wires. Therefore, to avoid interference between the phase coils due to incomplete shaping, the coil length needs to be increased. Utility Model Content

[0006] In view of this, in order to overcome the above-mentioned technical problems, this application provides a coil end forming device for round wire, a round wire motor, and a vehicle.

[0007] On one hand, a coil end forming device for round wire is provided, the coil end forming device being disposed at the axial end of a motor stator and capable of shaping a round wire coil extending to the axial end of the stator radially along the motor stator to avoid space at the axial end of the stator corresponding to a stator slot where no coil is embedded.

[0008] The coil end forming device includes: a blind angle coil pressing mechanism (such as...) Figure 2 210 shown) and support mechanism (such as Figure 2(As shown in 220). Along the radial direction of the stator, the blind angle coil pressing mechanism is located on the side closer to the center of the stator than the round wire coil. The blind angle coil pressing mechanism includes an expanding member (such as...). Figure 2 As shown in 2) and at least one inner mold (such as Figure 2 As shown in 1), the expanding member is configured to move radially along the stator. The at least one inner mold is disposed on the side of the expanding member away from the center of the stator and is configured to move toward the circular wire coil under the action of the expanding member to press the circular wire coil. Along the circumferential direction of the stator, the width of the inner mold is greater than the width of the stator slot. Along the radial direction of the stator, the support mechanism is disposed on the side away from the center of the stator relative to the circular wire coil. The support mechanism includes: an outer mold (e.g., Figure 2 As shown in 221), the outer mold and the inner mold cooperate to shape the circular coil.

[0009] In some embodiments, the inner mold includes a 3D contact surface for pressing the circular coil extending to the axial end of the stator. The 3D contact surface extends along the circumferential direction of the stator, and the shape of the 3D contact surface is adapted to the shape of the connecting line of the preset circular coil.

[0010] In some embodiments, the blind angle coil pushing mechanism further includes a T-shaped slider, through which the inner mold is connected to the diameter expansion component.

[0011] In some embodiments, the at least one inner mold includes a first inner mold and a second inner mold. The blind angle coil pressing mechanism further includes a guide configured to guide the first inner mold and the second inner mold to move radially along the stator while simultaneously moving circumferentially along the stator. The guide includes a first sub-guide, a second sub-guide, and a third sub-guide, the first sub-guide being disposed on one side of the expanding member along the circumferential direction of the stator. The second sub-guide is disposed on the other side of the expanding member along the circumferential direction of the stator.

[0012] The first sub-guide member and the third sub-guide member are disposed opposite to each other to form a first guide gap; the first inner mold and the T-shaped slider connected thereto are located between the first guide gap and move along the first guide gap under the drive of the diameter expansion member.

[0013] The second sub-guide member is disposed opposite to the third sub-guide member to form a second guide gap; the second inner mold and the T-shaped slider connected thereto are located between the second guide gap and move along the second guide gap under the drive of the diameter expansion member.

[0014] In some embodiments, the angle formed between the extending direction of the first guide gap and the extending direction of the second guide gap is an acute angle, and the intersection of the extending directions of the first guide gap and the second guide gap is closer to the circular coil than the midpoint of the stator.

[0015] In some embodiments, the width of the second inner mold is equal to the width of the first inner mold along the circumference of the stator, or the width of the second inner mold is greater than the width of the first inner mold along the circumference of the stator.

[0016] In some embodiments, the at least one inner mold includes a first inner mold and a second inner mold symmetrically arranged, and the first inner mold and the second inner mold are respectively fixed to the expanding member. The blind angle coil pushing mechanism further includes: a guide member located at one end of the expanding member along the axial direction of the stator near the stator, and configured to guide the expanding member to slide radially along the stator. The guide member includes: a fourth sub-guide member and a fifth sub-guide member arranged opposite to each other, and the expanding member moves radially along the stator under the guidance of the fourth sub-guide member and the fifth sub-guide member.

[0017] In some embodiments, the coil end forming device further includes a cone disposed at the center of the stator, the cone having a T-slot on its side corresponding to the diameter expanding member. A T-key is provided on the side of the diameter expanding member near the center of the stator, the T-key fitting into the T-slot. The cone moves axially along the stator, causing the T-key to slide in the T-slot while simultaneously driving the diameter expanding member to move radially along the stator.

[0018] In some embodiments, the coil end forming device further includes: a rotating mechanism disposed radially inside the stator, and the rotating mechanism extending circumferentially along the stator. The cone is movably disposed at the center of the rotating mechanism along the axial direction of the stator, and the blind angle coil pushing mechanism is connected to the axial end of the rotating mechanism. The rotating mechanism can drive the blind angle coil pushing mechanism to rotate circumferentially along the stator, and drive the cone to rotate circumferentially along the stator through the engagement of the T-key and the T-slot.

[0019] Secondly, a circular wire motor is provided, comprising: a rotor and a stator, wherein the ends of the circular wire coils within the stator are shaped by the aforementioned coil end forming device for circular wires.

[0020] Thirdly, a vehicle is provided, comprising: a vehicle body and the aforementioned circular wire motor. Attached Figure Description

[0021] Figure 1A This is a top view of a circular wire coil end forming device in related technologies;

[0022] Figure 1B This is a three-dimensional structural diagram of a circular wire coil end forming device in related technologies;

[0023] Figure 2 This is a top view of a blind angle coil pushing mechanism in a retracted state according to some embodiments;

[0024] Figure 3 This is a top view of a blind-angle coil pushing mechanism in an expanded state according to some embodiments;

[0025] Figure 4A This is a schematic diagram of the structure of an inner mold according to some embodiments;

[0026] Figure 4B This is a top view of another blind-angle coil pressing mechanism in a retracted state according to some embodiments;

[0027] Figure 5 This is a top view of another blind-angle coil pressing mechanism in an expanded state according to some embodiments;

[0028] Figure 6 This is a diagram illustrating the working process of a coil end forming device for round wire according to some embodiments;

[0029] Figures 7A-7C This is a diagram illustrating the working process of another coil end forming device for round wire according to some embodiments;

[0030] Figure 8 This is a schematic diagram of the structure of a powertrain according to some embodiments;

[0031] Figure 9 This is a structural schematic diagram of a vehicle according to some embodiments.

[0032] Figure label:

[0033] 10000, Vehicle; 1000, Powertrain; 2000, Wheel; 3000, Transmission Mechanism; 500, Reducer; 600, Circular Wire Motor;

[0034] 100. Stator; 101. Stator slot; 102. Stator teeth; 103. Round wire coil; 200. Three-dimensional coil end forming device for round wire;

[0035] 10. Thin flat push rod; 30. Blind corner area; 210. Blind corner coil pressing mechanism;

[0036] 1. Inner mold; 110. 3D contact surface; 13. First inner mold; 14. Second inner mold;

[0037] 2. Diameter expansion component; 23. T-key;

[0038] 3. Guide component; 31. First sub-guide component; 32. Second sub-guide component; 33. Third sub-guide component; 301. First guide gap; 302. Second guide gap; 34. Fourth sub-guide component; 35. Fifth sub-guide component;

[0039] 4. T-slider; 5. Cone; 51. T-slot; 9. Rotating mechanism;

[0040] 220. Supporting structure; 221. Outer mold. Detailed Implementation

[0041] The technical solutions of the embodiments of this application will be described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.

[0042] In the accompanying drawings of the embodiments of this application, solid structures such as parts and components are represented by guide lines; hollow structures such as openings, holes, spaces, and cavities are represented by guide lines with arrows.

[0043] To make the objectives, technical solutions, and advantages of this application clearer, the application will be described in further detail below with reference to the accompanying drawings.

[0044] like Figure 1A As shown, the stator 100 includes a plurality of stator teeth 102, and stator slots 101 are formed between adjacent stator teeth 102. The stator 100 also includes round wire coils 103, which are disposed in corresponding stator slots 101, and the connecting wires at the ends of the round wire coils 103 are located at the axial ends of the corresponding stator slots 101. The round wire coils 103 can be divided into three phases, for example, U phase, V phase, and W phase. During the winding process of the stator 100, the three-phase coils are sequentially inserted into the corresponding stator slots 101. In the following description, the sequential insertion of the U phase, V phase, and W phase is used as an example, but the embodiments of this utility model are not limited to this, and other insertion orders are also possible.

[0045] For circular wire motors, before inserting the V-phase and W-phase coils, it is necessary to reserve internal space and axial end space in the corresponding stator slots. The internal space is used to embed the coils, and the axial end space is used to set the connecting wires at the coil ends. Therefore, after inserting the U-phase or V-phase coil, the ends of the inserted coils must be shaped.

[0046] Reference Figure 1A-B. In the prior art, a thin flat push rod 10 is simply inserted into the stator slot 101 where the next phase coil will be inserted, and it is made to radially expand outward along the stator radial direction to cover the inserted round wire coil 103 on the stator slot 101. This has the following problems:

[0047] First, since the thickness of the thin flat push rod 10 along the circumference of the stator 100 is less than the width of the stator slot 101, when the front end of the thin flat push rod 10 contacts and pushes the round wire coil 103, the contact area between the two is small, so the pressure per unit area of ​​the contact surface is large, which can easily lead to damage to the coil.

[0048] When the thin flat push rod 10 pushes the round wire coil 103, since there is no corresponding support on the outside of the round wire coil 103, it is easy to stretch the round wire coil 103. Furthermore, the round wire coil 103 is pulled at the edge of the end face of the stator slot 101 and is easily scratched by the edge of the slot.

[0049] Since the path of the connecting wire of the next phase coil 103 to be inserted is a three-dimensional path, however, the front ends of the multiple thin flat push rods 10 only have a simple shape, and the connecting wire after its shaping cannot be adapted to the three-dimensional path of the next phase coil, in order to avoid interference with the next phase coil to be inserted, it is necessary to lengthen the length of the connecting wire at the end of the coil.

[0050] Furthermore, the two ends of the wire bundle at the end of the round wire coil are embedded in the stator slots directly below (perpendicular to the paper and inward). The thin flat push rod 10 can only push the stator slots adjacent to the stator slots where the round wire coil is embedded, but where no coil is inserted (hereinafter referred to as "empty slots"). Therefore, even if the thickness of the thin flat push rod is increased, it is impossible to ensure the top space between the empty slot and the stator slot where the coil is embedded. This space corresponds to the "axial extension of the wire bundle" which is crucial for the next phase coil, that is, there is a blind corner region 30 (see reference). Figure 1A This results in the coil not being fully formed;

[0051] Finally, the front end of the thin flat push rod 10 will retract after pressing the coil, and the coil that has been radially pressed will return to its original position during the next axial forming.

[0052] To address the aforementioned problems, some embodiments of this application provide a three-dimensional coil end forming device for circular wires. This device not only employs a method of pushing radially outwards towards the stator, but also incorporates a support structure on the outer side to clamp the coil from both the inner and outer sides, thereby preventing the coil from being scratched or stretched. Furthermore, by adding a guide, the movement direction of the push rod is adjusted to align with the path direction of the connecting wire, thus pressing down on blind corner areas. In addition, the three-dimensional coil end forming device includes an inner mold, the pressing surface of which is set to a 3D solid shape consistent with the preset shape of the connecting wire. This ensures that the path of the formed connecting wire is adapted to the path of the next phase coil.

[0053] Through the above improvements, compared with the existing technology, the coil length can be greatly shortened by 13mm per turn (13mm / loop).

[0054] Reference Figure 2 and Figure 3 The three-dimensional coil end former 200 for circular wires (hereinafter referred to as the three-dimensional coil end former) provided in some embodiments of this application is disposed at the axial end of the stator 100 of the motor and is configured to shape the circular wire coil 103 extending to the axial end of the stator 100 in the radial direction of the stator 100 so that the circular wire coil 103 avoids the space (e.g., top space) of the axial end of the stator corresponding to the stator slot where the coil is not embedded.

[0055] In some embodiments of this application, the three-dimensional coil end former 200 includes a blind corner coil pressing mechanism 210, which is disposed radially inside the circular coil 103 near the center of the stator 100 and is configured to shape the connecting wires of the circular coil 103 radially inside the circular coil 103.

[0056] The blind angle coil pressing mechanism 210 includes an expanding member 2 and at least one inner mold 1. The expanding member 2 is configured to move radially along the stator 100. The inner mold 1 is located on the side of the expanding member 2 away from the center of the stator 100. The inner mold 1 can move radially toward the circular coil 103 along the stator 100 under the drive of the expanding member 2 to shape the circular coil 103.

[0057] Reference Figure 3Along the circumference of the stator 100, the width of at least one inner mold 1 (e.g., W11, W12) is greater than the width W2 of the stator slot 101 of the stator 100. That is, the width W11 of the first inner mold 13 is greater than the width W2 of the stator slot 101 (i.e., W11>W2), and the width W12 of the second inner mold 14 is greater than the width W2 of the stator slot 101 (i.e., W12>W2). This reduces the contact pressure between the inner mold 1 and the coil, thereby preventing coil damage. Here, the width of the inner mold 1 refers to the dimension of the inner mold 1 along the circumference of the stator 100, and the width of the stator slot 101 refers to the dimension of the stator slot 101 along the circumference of the stator 100.

[0058] In some embodiments, the width W11 of the first inner mold 13 and the width W12 of the second inner mold 14 may be equal (W11 = W12). For example, refer to Figure 3 W11 = W12 > W2. At this time, the first inner mold 13 and the second inner mold 14 can be set symmetrically.

[0059] In some embodiments, the width W11 of the first inner mold 13 and the width W12 of the second inner mold 14 may not be equal. For example, refer to... Figure 6 The width W11 of the first inner mold 13 is greater than the width W12 of the second inner mold 14, so W11 > W12 > W2.

[0060] In some embodiments of this application, each inner mold 1 includes: a three-dimensional (3D) contact surface 110 (see reference 110). Figure 4A The 3D contact surface 110 is configured to contact the circular wire coil 103 (i.e., the connecting wire) extending to the axial end of the stator 100. The 3D contact surface 110 extends circumferentially along the stator 100 and is capable of abutting against the aforementioned blind corner region. For example, refer to... Figure 3 The inner mold 1, on the side near the "inserted coil" stator slot, can be positioned... Figure 1A The circular coil 103 in the corresponding blind corner region 30 is pushed so that the circular coil 103 can be retracted out of the top space corresponding to the blind corner region 30, thereby preventing the inserted circular coil 103 from interfering with the next phase coil to be inserted.

[0061] Understandably, in related technologies, there are blind corner areas 30 that cannot be pressed, which affects the installation of the next phase coil. Compared to related technologies, some embodiments of this application extend the 3D contact surface 110 along the circumference of the stator 100 and allow the 3D contact surface 110 to abut against the blind corner area, thereby enabling the shaping of the round wire coil 103 in the blind corner area that cannot be pressed in the related technologies. In this way, the "axially extended portion of the wire harness," which is crucial to the next phase coil, can be avoided, improving the shaping effect of the round wire coil 103, while also reducing the contact surface pressure between the inner mold 1 and the round wire coil 103 to avoid damaging the coil.

[0062] In some embodiments of this application, the shape of the 3D contact surface can be made according to the shape of the 3D path of the connecting line of the preset circular coil 103.

[0063] Compared to the prior art, some embodiments of this application design the shape of the 3D contact surface to be adapted to the shape of the connecting line of the preset circular coil 103. In this way, the inner mold 1 can shape the connecting line of the circular coil 103 into a 3D structure that adapts to the three-dimensional path of the next phase coil, thereby preventing interference to the next phase coil.

[0064] In some embodiments of this application, reference is made to Figure 2 and Figure 3 The blind angle coil pushing mechanism 210 also includes a T-shaped slider 4, through which the inner mold 1 is connected to the diameter expansion component 2.

[0065] In some embodiments of this application, reference is made to Figure 3 At least one inner mold 1 includes a first inner mold 13 and a second inner mold 14. The first inner mold 13 can be configured to press against the bend on one side of the stator 100 along the circumference of the same phase coil; the second inner mold 14 can be configured to press against the bend on the other side of the stator 100 along the circumference of the same phase coil. This facilitates shaping of the blind corner area near the bottom stator slot 101 of the previously inserted round coil 103's connecting wire, opening up the top space of the empty stator slot 101 into which the next phase round coil will be inserted. Simultaneously, it also ensures the installation path of the connecting wire of the next phase round coil.

[0066] In some embodiments of this application, reference is made to Figure 4B and Figure 5 The blind angle coil pushing mechanism 210 further includes a guide 3, which is configured to guide the first inner mold 13 and the second inner mold 14 to move radially along the stator 100 and circumferentially along the stator 100. The guide 3 includes a first sub-guide 31, a second sub-guide 32, and a third sub-guide 33.

[0067] The first sub-guide 31 and the second sub-guide 32 are located on both sides of the expanding member 2 along the circumference of the stator 100. The third sub-guide 33 is located between the first sub-guide 31 and the second sub-guide 32.

[0068] The first sub-guide 31 and the third sub-guide 33 are disposed opposite to each other to form a first guide gap 301 (see reference). Figure 5 The first inner mold 13 and the T-shaped slider 4 connected thereto are located between the first guide gap 301, and can move along the first guide gap 301 under the drive of the diameter expansion component 2.

[0069] The second sub-guide 32 is disposed opposite to the third sub-guide 33 to form a second guide gap 302 (see reference). Figure 5 The second inner mold 14 and the T-shaped slider 4 connected thereto are located between the second guide gaps 302, and can move along the second guide gaps 302 under the drive of the diameter expansion component 2.

[0070] In some embodiments of this application, the angle formed between the extending direction of the first guide gap 301 and the extending direction of the second guide gap 302 is an acute angle (e.g., Figure 5 (The angle φ is shown). For example, φ can be 60°. This allows the first inner mold 13 and the second inner mold 14 to expand circumferentially along the stator 100 as they move radially along the stator 100. By setting the aforementioned included angle to an acute angle, which facilitates pushing the inner mold 1 into the blind corner region and shaping the blind corner region, the shaping effect of the inner mold 1 is improved.

[0071] Furthermore, the intersection of the extending direction of the first guide gap 301 and the extending direction of the second guide gap 302 (e.g.) Figure 5 Point E shown), compared to the midpoint of stator 100 (e.g., point E), Figure 5 Point C (as shown) is positioned closer to the circular coil 103. That is, the angle φ is greater than the shaping angle of the thin flat push rod in the related art.

[0072] Thus, compared to Figure 1A According to the related technologies shown, under the same radial movement distance, the first inner mold 13 and the second inner mold 14 of some embodiments of this application can move a greater distance along the circumference of the stator 100, which is beneficial for pushing and shaping the blind corner area.

[0073] In related technologies, the round wire coil 103 is formed by pressing. During the process of pushing the round wire coil 103 radially outward from the stator 100, the round wire coil 103 will be pulled out from the opening of the stator slot 101 located on the axial end face of the stator 100. This can easily cause the round wire coil 103 to be damaged or stretched.

[0074] Reference Figure 2 and Figure 3 The three-dimensional coil end forming device 200 further includes a support mechanism 220, which includes an outer mold 221 disposed on the side of the circular coil 103 away from the stator center. The outer mold 221 cooperates with the inner mold 1 to compress the circular coil 103. In this way, instead of the push forming method in related technologies, the circular coil 103 is compressed and formed by the cooperation of the inner mold 1 and the outer mold 221, thereby avoiding damage or stretching of the circular coil 103 and shortening the length of the formed circular coil 103.

[0075] In some embodiments of this application, reference is made to Figure 6 The three-dimensional coil end forming device 200 also includes a cone 5, which is disposed at the center of the stator 100 and can be coaxially disposed with the stator 100. The cone 5 is provided with a T-slot 51, and a T-key 23 is provided on the side of the diameter expansion member 2 near the center of the stator 100, and the T-key 23 is fitted into the T-slot 51.

[0076] As the cone 5 moves along the axial direction of the stator 100, it can drive the T-key 23 to slide relative to the cone 5 while moving radially along the stator 100.

[0077] For example, the cone moves along the axial direction of the stator 100 in a direction perpendicular to the paper and outward (hereinafter referred to as the first direction) to drive the T-key to move radially outward of the stator 100, thereby realizing the movement of the diameter expansion component 2 and the inner mold 1 radially outward of the stator 100 to shape the circular wire coil 103.

[0078] The cone moves along the axial direction of the stator 100 in a direction perpendicular to the paper and inward (hereinafter referred to as the second direction) to drive the T-key to move radially inward to the stator 100, thereby realizing the movement of the expansion component 2 and the inner mold 1 to the radially inward of the stator 100.

[0079] The cone 5 can be a cone or a pyramid, and this application does not limit it.

[0080] Reference Figures 7A-7C In some embodiments of this application, the three-dimensional coil end forming device 200 further includes a rotating mechanism 9. The rotating mechanism 9 is disposed radially inside the stator 100 and has an annular structure. The cone 5 is movably disposed at the center of the annular rotating mechanism along the axial direction of the stator 100. The blind angle coil pushing mechanism 210 can be fixed to the axial end of the rotating mechanism 9. The blind angle coil pushing mechanism 210 can also rotate circumferentially around the stator 100 under the drive of the rotating mechanism 9, and drive the cone 5 to rotate circumferentially around the stator 100 through the engagement of the T-key 23 and the T-slot 51.

[0081] For example, the guide 3 of the blind angle coil pressing mechanism 210 is fixed to the axial end of the rotating mechanism 9. In this way, the rotating mechanism 9 can provide axial support for the guide 3, the diameter expansion component 2, and the inner mold 1, and the guide 3 is fixedly set with the rotating mechanism 9, which facilitates the movement of the diameter expansion component 2 and the inner mold 1 relative to the guide 3.

[0082] In related technologies, after the thin flat push rod 10 presses the circular coil 103, it retracts to the radially inner side of the stator 100. Thus, when the circular coil 103 is subsequently axially formed, the circular coil 103 that was radially pressed will return to its original position, which may cause the shape of the radially expanded circular coil 103 to become distorted.

[0083] In some embodiments of this application, the three-dimensional coil end forming device 200 performs axial forming operations on the circular coil 103 while expanding the diameter of the circular coil. This allows for axial forming while maintaining the diameter expansion of the circular coil 103, thereby preventing twisting of the circular coil 103 and improving the shaping effect of the circular coil 103.

[0084] The following example uses the shaping of the U-phase coil, combined with the attached... Figure 4B The working process of the three-dimensional coil end forming device 200 provided in some embodiments of this application will be described.

[0085] In some embodiments of this application, the blind angle coil pushing mechanism 210 has a contracted state and an expanded state.

[0086] In the initial state, that is, when there is no need to shape the end of the circular coil 103, the blind angle coil pushing mechanism 210 is in a retracted state.

[0087] Reference Figure 4B In the contracted state, the expanding member 2 is located near the center of the stator 100. The first inner mold 13 and the second inner mold 14 are close to each other. The first inner mold 13 is located within the first guide gap 301, and the second inner mold 14 is located within the second guide gap 302.

[0088] When shaping the end of the circular coil 103, the blind angle coil pushing mechanism 210 is adjusted from the contracted state to the expanded state.

[0089] The blind-angle coil pushing mechanism 210 expands radially along the stator 100. The cone 5 moves in a first direction, causing the expanding member 2 to drive the inner mold 1 from a position near the center of the stator 100, moving radially away from the center of the stator 100. During this movement, the first inner mold 13 and the second inner mold 14 move away from each other under the guidance of the guide member 3. For example, refer to... Figure 5The first inner mold 13 moves along the first guide gap 301 toward the blind corner area on one side of the circumferential direction near the circular coil 103 and is finally pressed. The second inner mold 14 moves along the second guide gap 302 toward the blind corner area on the other side of the circumferential direction near the circular coil 103 and is finally pressed.

[0090] In this way, the inner mold 1 can push the end of the round wire coil 103 from the inside of the round wire coil 103 near the center of the stator 100. This pushes away the connecting wire of the round wire coil 103 previously inserted near the stator slot, opening the top of the empty stator slot into which the next phase coil will be inserted. At the same time, it also ensures the installation path of the connecting wire of the next phase round wire coil.

[0091] Furthermore, the outer mold 221 of the support mechanism 220 located on the side of the circular coil 103 away from the center of the stator, when the inner mold 1 pushes the end of the circular coil 103, abuts against the end of the circular coil 103 on the outside of the circular coil 103 away from the center of the stator 100 and pushes it in the opposite direction.

[0092] In this way, the inner mold 1 of the blind angle coil pressing mechanism 210 and the outer mold 221 of the support mechanism 220 cooperate with each other to shape the end of the circular coil 103 through compression. The support mechanism 220 provides support for the outer side of the circular coil 103, which can prevent the circular coil 103 from being overstretched, thereby shortening the length of the end of the circular coil 103.

[0093] After the end of the circular coil 103 is shaped, the blind angle coil pushing mechanism 210 is adjusted from the expanded state to the contracted state.

[0094] The blind-angle coil pressing mechanism 210 retracts radially along the stator 100, and the cone 5 moves in the second direction, causing the diameter expanding member 2 to move radially toward the center of the stator 100 from a position away from the center of the stator 100. During the movement, the first inner mold 13 and the second inner mold 14 move toward each other under the guidance of the guide 3. The first inner mold 13 moves toward the center of the stator 100 along the first guide gap 301, and the second inner mold 14 moves toward the center of the stator 100 along the second guide gap 302. Until the first inner mold 13 retracts into the first guide gap 301 and the second inner mold 14 retracts into the second guide gap 302.

[0095] This completes the shaping process of the U-phase coil.

[0096] It should be noted that, for the case of shaping the U-phase coil, the number of blind angle coil pushing mechanisms 210 can be the same as or less than the number of coil groups that need to be shaped.

[0097] For example, there are three blind-angle coil pressing mechanisms 210, and the number of coil groups that need to be shaped is also three (see reference). Figures 4B to 5 ).

[0098] Alternatively, the blind angle coil pressing mechanism 210 has 4 units, requiring 8 groups of coils to be shaped (refer to...). Figure 6 ).

[0099] When the number of blind angle coil pressing mechanisms 210 is the same as the number of coil groups that need to be shaped, the blind angle coil pressing mechanism 210 of the three-dimensional coil end forming machine 200 can complete the shaping of the coil after one expansion process.

[0100] When the number of blind-angle coil pressing mechanisms 210 differs from the number of coil groups requiring shaping, the blind-angle coil pressing mechanisms 210 of the three-dimensional coil end forming machine 200 need to undergo multiple expansion processes to complete the coil shaping. Figure 6 For example, during the first expansion process, the blind angle coil pushing mechanism 210 shapes 4 of the 8 groups of circular coils. Afterward, the blind angle coil pushing mechanism 210 can rotate by a preset angle, such as counterclockwise, driven by the rotating mechanism 9. During the second expansion process, it shapes the other 4 of the 8 groups of circular coils.

[0101] In addition, the rotating mechanism 9 is connected to a driving mechanism, which can drive the rotating mechanism 9 to rotate circumferentially along the stator 100. The rotating mechanism 9 drives the guide 3 to rotate, which in turn drives the expansion component 2 and the inner mold 1 to rotate, and drives the cone 5 to rotate through the engagement of the T-key 23 and the T-slot 51, thereby realizing the rotation of the blind angle coil pushing mechanism 210.

[0102] Some embodiments of this application also provide another blind-angle coil pressing mechanism 210, which differs from the embodiments described above in that the guide 3 is configured to guide the expansion member 2 to move radially along the stator 100. For example, the guide 3 may be located at one end of the expansion member 2 near the rotating mechanism 9.

[0103] For example, refer to Figure 7B The guide member 3 may include a fourth sub-guide member 34 and a fifth sub-guide member 35, which are arranged opposite to each other and fixed to the rotating mechanism 9. For example, the fourth sub-guide member 34 and the fifth sub-guide member 35 are arranged in parallel. The diameter-expanding member 2 is capable of moving radially under the guidance of the fourth sub-guide member 34 and the fifth sub-guide member 35.

[0104] It should be noted that the maximum distance between the first inner mold 13 and the second inner mold 14 can be set according to the distance of the blind corner area of ​​the circular coil to be shaped. This ensures that the corresponding blind corner area can be pressed, thereby ensuring the shaping effect of the circular coil. In addition, by adjusting the distance between the two inner molds 1 or the included angle of the extension direction of the two inner molds 1, the required shaping angle can also be ensured.

[0105] The following example uses the shaping of the V-phase coil, combined with the attached... Figures 7A-7C The working process of the three-dimensional coil end forming device 200 provided in some embodiments of this application will be described.

[0106] It should be noted that after the V-phase coil is embedded, only the V-phase coil can be shaped, or both the embedded U-phase and V-phase coils can be shaped together to ensure the installation path of the W-phase coil. The latter will be used as an example below.

[0107] In the initial operating state of the three-dimensional coil end forming device 200, the blind angle coil pushing mechanism 210 of the three-dimensional coil end forming device 200 is in a retracted state. The blind angle coil pushing mechanism 210 is located radially inside the stator 100. The support mechanism 220 is located radially outside the stator 100.

[0108] When it is necessary to shape the round wire coil 103, the blind angle coil pushing mechanism 210 is... Figure 7A The contraction state shown indicates a transition to an expansion state.

[0109] Specifically, the cone 5 moves along the first direction, causing the diameter-expanding component 2 to move radially outward under the guidance of the guide 3. The diameter-expanding component 2 drives the first inner mold 13 and the second inner mold 14 to move radially towards the circular coil 103, so as to shape part of the blind corner area of ​​the circular coil 103, such as... Figure 7B As shown.

[0110] Furthermore, the outer mold 221 of the support mechanism 220, located on the side of the circular coil 103 away from the stator center, abuts against the end of the circular coil 103 on the outer side away from the stator center and applies pressure in the opposite direction when the first inner mold 13 and the second inner mold 14 press the end of the circular coil 103. In this way, the inner mold 1 of the blind angle coil pressing mechanism 210 and the outer mold 221 of the support mechanism 220 cooperate to shape the end of the circular coil 103 through compression.

[0111] At the end of the first shaping of the circular coil 103, the blind angle coil pushing mechanism 210 is as follows: Figure 7B The expansion state shown is adjusted as follows Figure 7A The contraction state is shown.

[0112] Specifically, the cone 5 moves along the second direction, causing the expanding member 2 to move radially inward toward the stator 100 under the guidance of the guide 3. The expanding member 2 drives the first inner mold 13 and the second inner mold 14 to move radially toward the center of the stator 100 until the first inner mold 13 and the second inner mold 14 contract to... Figure 7A The contraction state is shown.

[0113] Reference Figure 7C The blind angle coil pushing mechanism 210 rotates by a preset angle and repeats the above process to perform a second shaping process, in order to shape the remaining blind angle area in the round wire coil. This completes the shaping of the V-phase coil.

[0114] Some embodiments of this application also provide a circular wire motor 600, including a rotor and a stator 100, wherein the ends of the circular wire coils of the stator 100 are shaped by a three-dimensional coil end former 200 for circular wires.

[0115] Some embodiments of this application also provide a vehicle 10000, which includes a vehicle body and the aforementioned circular motor 600.

[0116] Reference Figure 9 The vehicle 10000 includes wheels 2000 and a powertrain 1000. The powertrain 1000 is used to drive the wheels 2000 to rotate, thereby enabling the vehicle 10000 to move.

[0117] Reference Figure 9 The vehicle 10000 also includes a transmission mechanism 3000, which is used to drive the powertrain 1000 and the wheels 2000. The powertrain 1000 converts electrical energy into mechanical energy and drives the wheels 2000 to rotate through the transmission mechanism 3000, thereby enabling the vehicle 10000 to move.

[0118] exist Figure 9 In the given embodiment, the powertrain 1000 is used to drive the rear wheels (wheels 2000 on the side closest to the rear of the vehicle) of the vehicle 10000 to rotate, and the front wheels of the vehicle 10000 are used to achieve steering. The vehicle 10000 is more responsive when steering and more stable when cornering.

[0119] In other embodiments, the powertrain 1000 is used to drive the front wheels (wheels 2000 on the side closest to the front of the vehicle) of the vehicle 10000 to rotate. The front wheels are used to achieve driving and steering. The front-wheel drive system has a simple structure, fewer parts, lighter weight, reduced power loss, higher transmission efficiency, and lower fuel consumption and cost.

[0120] Reference Figure 8The structure shown in the dashed box is the powertrain 1000, which includes a circular wire motor 600 and a reducer 500. The circular wire motor 600 and the reducer 500 are connected in a transmission connection. The circular wire motor 600 converts electrical energy into rotational mechanical energy and outputs torque to the reducer 500. The reducer 500 includes a gear set (not shown). The reducer 500 reduces the rotational speed and increases the torque through the gear set, and transmits the power to the transmission mechanism 3000. The transmission mechanism 3000 then transmits the power to the wheel 2000 to drive the wheel 2000 to rotate.

[0121] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any changes or substitutions 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 coil end forming device for round wire, characterized in that, The coil end forming device is located at the axial end of the motor stator and can shape the round wire coil extending to the axial end of the stator radially to avoid the space of the axial end of the stator corresponding to the stator slot where the coil is not embedded. The coil end forming device includes: A blind-angle coil pressing mechanism is disposed along the radial direction of the stator, on a side closer to the center of the stator than the circular coil, and the blind-angle coil pressing mechanism includes: The diameter-expanding component is configured to move radially along the stator; and At least one inner mold is disposed on the side of the expanding member away from the center of the stator and is configured to move toward the circular wire coil under the action of the expanding member to press the circular wire coil; the width of the inner mold is greater than the width of the stator slot along the circumference of the stator; and A support mechanism is disposed along the radial direction of the stator on a side away from the center of the stator relative to the circular coil; the support mechanism includes an outer mold that cooperates with the inner mold to shape the circular coil.

2. The coil end forming device for round wire according to claim 1, characterized in that, The inner mold includes a 3D contact surface for pressing the circular coil extending to the axial end of the stator. The 3D contact surface extends circumferentially along the stator, and the shape of the 3D contact surface is adapted to the shape of the connecting line of the preset circular coil.

3. The coil end forming device for round wire according to claim 2, characterized in that, The blind angle coil pushing mechanism further includes a T-shaped slider, through which the inner mold is connected to the diameter expansion component.

4. The coil end forming device for round wire according to claim 3, characterized in that, The at least one inner mold includes a first inner mold and a second inner mold; The blind angle coil pushing mechanism further includes: a guide, configured to guide the first inner mold and the second inner mold to move radially along the stator while moving circumferentially along the stator; The guide includes: The first sub-guide is disposed on one side of the expanding member along the circumference of the stator; A second sub-guide is disposed on the other side of the expanding member along the circumference of the stator; and Third sub-boot; The first sub-guide member and the third sub-guide member are arranged opposite to each other to form a first guide gap; the first inner mold and the T-shaped slider connected thereto are located between the first guide gap, and move along the first guide gap under the drive of the diameter expansion member; The second sub-guide member is disposed opposite to the third sub-guide member to form a second guide gap; the second inner mold and the T-shaped slider connected thereto are located between the second guide gap and move along the second guide gap under the drive of the diameter expansion member.

5. The coil end forming device for round wire according to claim 4, characterized in that, The angle formed between the extension direction of the first guide gap and the extension direction of the second guide gap is an acute angle, and the intersection of the extension direction of the first guide gap and the extension direction of the second guide gap is closer to the circular coil than the center point of the stator.

6. The coil end forming device for round wire according to claim 5, characterized in that, Along the circumferential direction of the stator, the width of the second inner mold is equal to the width of the first inner mold; or Along the circumference of the stator, the width of the second inner mold is greater than the width of the first inner mold.

7. The coil end forming device for round wire according to claim 2, characterized in that, The at least one inner mold includes a first inner mold and a second inner mold arranged symmetrically, and the first inner mold and the second inner mold are respectively fixed to the diameter expansion component; The blind angle coil pushing mechanism further includes: a guide member located at one end of the expanding member along the axial direction of the stator near the stator, and configured to guide the expanding member to slide radially along the stator. The guide member includes: a fourth sub-guide member and a fifth sub-guide member disposed opposite to each other, and the expanding member moves radially along the stator under the guidance of the fourth sub-guide member and the fifth sub-guide member.

8. The coil end forming device for round wire according to any one of claims 1-7, characterized in that, The coil end forming device for round wire further includes: a cone, the cone being disposed at the center of the stator, and the side of the cone being provided with a T-groove corresponding to the diameter expansion component; A T-key is provided on the side of the diameter expansion component near the center of the stator, and the T-key is fitted into the T-groove; The cone moves along the axial direction of the stator, so that the T-key slides in the T-groove while driving the diameter expansion component to move radially along the stator.

9. The coil end forming device for round wire according to claim 8, characterized in that, The coil end forming device further includes: a rotating mechanism disposed on the radial inner side of the stator, and the rotating mechanism having an annular structure; the cone being movably disposed on the inner diameter side of the rotating mechanism along the axial direction of the stator; the blind angle coil pushing mechanism being fixed to the axial end of the rotating mechanism; the rotating mechanism being able to drive the blind angle coil pushing mechanism to rotate circumferentially along the stator, and driving the cone to rotate circumferentially along the stator through the engagement of the T-key and the T-slot.

10. A circular wire motor, characterized in that, The circular wire motor includes: Rotor; and The stator, wherein the ends of the round wire coils within the stator are shaped by a coil end forming device for round wires according to any one of claims 1-9.

11. A vehicle, characterized in that, The vehicles include: Vehicle body; and The circular wire motor according to claim 10.

Images