Stator wave winding forming method and apparatus

Abstract

The present invention provides a method and apparatus for forming stator wave windings. [Solution] The stator wave winding forming method includes sequentially performing 2D forming, 3D preforming, and 3D press forming steps, and the equipment used in the process includes a 2D forming apparatus, a 3D preforming apparatus, and a 3D press forming apparatus. Processing the 2D wave winding into an annular or coil shape makes the overall structure of the winding more stable, facilitates subsequent pressing operations, avoids winding disorder and misalignment, and by processing the 2D wave winding into a coil shape, the wire material can be distributed more uniformly, its arrangement density can be adjusted, the utilization rate of the stator lot can be optimized, and the power density and efficiency of the motor can be further improved. After the 2D wave winding is coiled, the coil forms a closed overall structure, which can more accurately hold the position of the winding during pressing and reduce the risk of deformation and misalignment.

Description

Technical Field

[0001] The present invention belongs to the field of coil forming equipment, and specifically relates to a stator coil forming method and equipment.

Background Art

[0002] Among many manufacturing methods, the coil 3D forming technology is usually direct three-dimensional forming, that is, in the slots of the stator or in the winding space, the wire is directly placed in a three-dimensional space structure according to the trajectory of the wave.

[0003] However, for the design of a specific stator (such as windings outside the slots or a stator with a special shape), when directly 3D press-forming the stator coil, the needs of a specific stator shape cannot be met.

[0004] Therefore, a method of first 2D-forming a coil with a complex shape and then performing 3D pressing is adopted to meet the manufacturing needs of a specific stator, but a new problem is faced.

[0005] After the 2D coil is processed, the wire is loose and easily deformed. When directly used for 3D forming, the coil shape becomes uncontrollable, affecting the motor performance.

[0006] Therefore, there is a need for a method and equipment that can ensure that the 2D-formed stator coil does not deform after 3D press-forming while satisfying the stator coil formed into a specific shape by 2D forming.

Summary of the Invention

Means for Solving the Problems

[0007] In view of the above problems, the present invention provides a stator coil forming method, and this stator coil forming method includes: S1. Placing a straight coil in a 2D forming device, and realizing one-step forming of the 2D coil by simultaneously extruding both sides of the straight coil; S2, a step of placing the 2D wave winding in a 3D pre-forming machine and performing a pre-winding process to form a wave winding sleeve after 2D forming, S3, the step of covering the wave winding sleeve with a 3D press forming machine, pressing the upper and lower ends of the adjusted 2D wave winding after pre-winding to form the final wave winding, S4 includes the step of repeating steps S1-S3 to form the required wave windings and placing them one by one on a winding machine to manufacture stator coils.

[0008] Furthermore, the aforementioned preliminary winding process is S2-1, a step in which the 2D wave winding formed in a planar shape by the 2D molding apparatus is transported to the 3D pre-molding equipment to prepare for pre-molding, S2-2, a step of sequentially winding each bent end of a planar 2D wave winding onto the surface of a 3D preforming machine, S2-3 includes the step of completely winding a planar 2D wave winding onto the surface of a 3D preforming machine to form a wave winding sleeve.

[0009] The present invention further discloses a stator wave winding forming apparatus used in the above-described stator wave winding forming method, which includes a 2D forming apparatus, a 3D pre-forming apparatus, and a 3D press forming apparatus that are sequentially mounted on the same table. The 2D molding apparatus includes a moving means attached to the top of a table, a molding means and a moving end forming wire folding means attached to and driven by the top of the moving means, and a fixed end forming wire folding means attached to the top of the table and cooperating with the molding means to fix the wave winding, The 3D pre-molding equipment includes an adjustment jacking means and a pre-winding means mounted on the top of the table, The 3D press forming machine includes a support assembly mounted on the top of the table, and a press assembly surrounding the outside of the support assembly.

[0010] Furthermore, the forming means is used to press the ends of the wave winding, and the moving end forming wire folding means is used to fold a straight line into a wave winding.

[0011] Furthermore, the adjustment jacking means is used to transport the 2D-formed wave winding to the bottom of the pre-winding means, and the pre-winding means is used to pre-wind the 2D-formed wave winding.

[0012] Furthermore, the support assembly is used to cover the wave winding sleeve after the pre-winding process, and the press assembly is used to press-form the wave winding sleeve in a press die fixed to the outer circumference of the support assembly. [Effects of the Invention]

[0013] The present invention has the following beneficial effects compared to the prior art. 1. Equipped with a stable winding structure: Pre-winding treatment improves winding stability and reduces the risk of direct pressing. 2. Optimized winding performance: The combination of coil preforming and press forming improves the winding's filling density, mechanical strength, and heat dissipation performance. 3. Can meet complex needs: The stepwise method is more flexible and suitable for complex stator designs and three-dimensional geometric forms. 4. Improve production feasibility: The multi-stage method reduces errors and improves the consistency and efficiency of motor production. 5. Processing 2D wave windings into annular or coil shape makes the overall structure of the winding more stable, facilitating subsequent pressing operations, avoiding winding irregularities and misalignment, and allowing for more uniform distribution of wire material, adjusting the arrangement density, optimizing status lot utilization, and further improving the motor's power density and efficiency. After coiling the 2D wave windings, the coil forms a closed overall structure, allowing for more accurate winding positioning during pressing and reducing the risk of deformation and misalignment. [Brief explanation of the drawing]

[0014] [Figure 1] This is a schematic diagram of the 2D wave winding in the present invention. [Figure 2]It is a schematic diagram of a pre-wound coil in the present invention. [Figure 3] It is a schematic diagram of the final coil in the present invention. [Figure 4] It is a perspective schematic diagram under the operating state of a 2D forming device. [Figure 5] It is a perspective schematic diagram under the operating state of a 3D preforming device. [Figure 6] It is a perspective schematic diagram under the operating state of a 3D press forming device. [Figure 7] It is a perspective schematic diagram after the operating state of a 2D forming device. [Figure 8] It is a perspective schematic diagram after the operating state of a 3D preforming device. [Figure 9] It is a perspective schematic diagram after the operating state of a 3D press forming device.

Embodiments for Carrying out the Invention

[0015] To facilitate the understanding of the present invention, the device of the present invention will be described in more detail below with reference to the accompanying drawings related thereto. The accompanying drawings show embodiments of the device. However, this device can be realized in many different forms and is not limited to the embodiments described in this specification. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present invention more complete.

[0016] In the description of the present invention, unless otherwise clearly defined and limited, the terms "attachment", "connection", and "installation" should be understood in a broad sense. For example, it may be a fixed connection, a fixed installation, a removable connection, a removable installation, or an integral connection, or an integral installation. A person skilled in the art can specifically understand the specific meaning of the above terms in the present invention.

[0017] Embodiment As shown in FIGS. 1-3, this embodiment provides a stator coil forming method, and this stator coil forming method includes the following steps.

[0018] As shown in Figure 1, S1, a single straight wave winding is placed in the 2D molding apparatus 11, and by simultaneously extruding both sides of the straight wave winding, one-step molding of the 2D wave winding is achieved.

[0019] S2, the 2D wave winding is placed in the 3D pre-forming machine 22 and pre-winding is performed.

[0020] S2-1, The 2D wave winding formed in a planar shape by the 2D molding device is transported to the 3D pre-molding device 22 for pre-molding preparation.

[0021] S2-2, each bent end of the planar 2D wave winding is wound sequentially around the surface of the 3D preforming machine 22.

[0022] As shown in Figure 2, in S2-3, a planar 2D wave winding is completely wound around the surface of the 3D pre-forming machine 22 to form a wave winding sleeve.

[0023] As shown in Figure 3, S3, the wave winding sleeve is placed over the 3D press forming machine 33, and the upper and lower ends of the adjusted 2D wave winding after the pre-winding process are pressed to form the final wave winding.

[0024] Steps S4 and S1-S3 are repeated to form the required wave windings, which are then placed one by one on the winding machine to manufacture the stator coil.

[0025] The equipment used in the above process is specifically a 2D molding machine 11, a 3D pre-molding machine 22, and a 3D press molding machine 33, which are sequentially mounted on the same table.

[0026] As shown in Figures 4 and 7, the 2D molding apparatus 11 includes a moving means 2 attached to the top of a table, a molding means 3 and a moving end forming line folding means 4 attached to and driven by the top of the moving means 2, and a fixed end forming line folding means 5 attached to the top of the table and cooperating with the molding means 3 to fix the wave winding. In detail, the molding means 3 is used to press the end of the wave winding, and the moving end forming line folding means 4 is used to drive a straight line with the moving means 2 and gradually bring it closer to the fixed end forming line folding means 5, thereby pushing the straight line to fold into a wave winding.

[0027] As shown in Figures 5 and 8, the 3D pre-forming machine 22 includes an adjustment jacking means 6 and a pre-winding means 7 mounted on the top of the table. More specifically, the adjustment jacking means 6 is used to transport the 2D-formed bent wave winding to the bottom of the pre-winding means 7. As the pre-winding means 7 rotates, it hooks and winds the wave winding at the bottom, forming a wave winding sleeve, thereby enabling the pre-winding process of the 2D-formed bent wave winding.

[0028] As shown in Figures 6 and 9, the 3D press forming machine 33 includes a support assembly 8 mounted on the top of the table, and a press assembly 9 surrounding the outside of the support assembly 8. More specifically, the pre-winding process of the wave winding sleeve covers the outside of the support assembly 8, and the press assembly 9 is used to press form the wave winding sleeve in a press die fixed to the outer circumference of the support assembly 8 to obtain the final wave winding. However, there only needs to be a one-to-one correspondence between the press assembly 9 and the press die (for example, press assemblies 9 and press dies provided in different shapes, angles, and positions).

[0029] Furthermore, the structure of the present invention can be realized in multiple different forms and is not limited to the embodiments described above. Any equivalent transformation performed by those skilled in the art using the description and drawings of the present invention, or any application of such equivalent transformation directly or indirectly to other related technical fields (e.g., the field of attaching and detaching other articles), is within the scope of protection of the present invention. [Explanation of Symbols]

[0030] 11 2D molding equipment 22 3D Premolding Equipment 33 3D press molding equipment 2. Means of transportation 3 Molding means 4. Moving end forming line folding means 5. Fixed end forming line folding means 6. Adjustment jacking means 7. Pre-winding means 8. Support Assembly 9 Press Assembly

Claims

1. A method for forming stator wave windings, S1, a step in which a straight wave winding is placed in a 2D molding apparatus (11), and both sides of the straight wave winding are simultaneously extruded to achieve one-step molding of the 2D wave winding, S2, The step of placing the 2D wave winding in a 3D pre-forming machine (22) and performing a pre-winding process to form a wave winding sleeve after 2D forming, S3, the step of covering the wave winding sleeve with a 3D press forming machine (33), pressing the upper and lower ends of one pre-winded 2D wave winding to form the final wave winding, A method for forming a stator wave winding, characterized by comprising the steps of repeating steps S4 and S1-S3 to form the required wave windings and placing them one by one in a winding machine to manufacture a stator coil.

2. The aforementioned preliminary winding process is S2-1, A step in which the 2D wave winding formed in a planar shape by the 2D molding apparatus is transported to the 3D pre-molding apparatus (22) to prepare for pre-molding, S2-2, a step of sequentially winding each bent end of the planar 2D wave winding onto the surface of the 3D pre-forming machine (22), The stator wave winding forming method according to claim 1, characterized by comprising the steps of S2-3, completely winding a planar 2D wave winding onto the surface of a 3D pre-forming machine (22) to form a wave winding sleeve.

3. A stator wave winding forming method according to claim 1-2, used in a stator wave winding forming machine, comprising a 2D forming device (11), a 3D pre-forming device (22), and a 3D press forming device (33) sequentially mounted on the same table, The 2D molding apparatus (11) includes a moving means (2) attached to the top of the table, a molding means (3) and a moving end forming wire folding means (4) attached to the top of the moving means (2) and driven by it, and a fixed end forming wire folding means (5) attached to the top of the table and working in cooperation with the molding means (3) to fix the wave winding, The 3D pre-molding machine (22) includes an adjustment jacking means (6) and a pre-winding means (7) attached to the top of the table, A method for forming a stator wave winding, characterized in that the 3D press forming machine (33) includes a support assembly (8) attached to the top of a table, and a press assembly (9) surrounding the outside of the support assembly (8).

4. The stator wave winding forming apparatus according to claim 3, characterized in that the forming means (3) is used to press the end of the wave winding, and the moving end forming wire folding means (4) is used to fold a straight line into a wave winding.

5. The stator wave winding forming apparatus according to claim 3, characterized in that the adjustment jacking means (6) is used to transport the 2D-formed wave winding to the bottom of the pre-winding means (7), and the pre-winding means (7) is used to pre-wind the 2D-formed wave winding.

6. The stator wave winding forming apparatus according to claim 3, characterized in that the support assembly (8) is used to cover the wave winding sleeve after the pre-winding process, and the press assembly (9) is used to press-form the wave winding sleeve in a press die fixed to the outer circumference of the support assembly (8).

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