Comb device and method of use for housing a hairpin that is to be subsequently moved into a slot in the motor stator.

Abstract

A comb device for housing a group of hairpins (H) to be subsequently moved into slots of a motor stator includes a cylindrical comb core (2-2) having a circumferential array of uniformly distributed axial slots (2-23) into which multiple hairpins (H) can be inserted. The axial slots (2-23) of the comb core (2-2) also open radially outward through apertures (2-24) on the side (2-21) of the comb core (2-2). A circumferential array of clamp elements (2-12) is mounted radially slidably within the slots (2-23) through the apertures (2-24). A drive mechanism can simultaneously drive the radial motion of all clamp elements (2-12) within each slot (2-23). The clamping element (2-12) is moved radially outward while the hairpins (H) are inserted into the slots (2-23) of the comb core (2-2), gradually leaving a wider radial space within the slots (2-23) for the hairpins (H) to be positioned within the slots (2-23). ​​Once all the hairpins (H) are positioned within the comb core (2-2), the upper lifting plate (2-6) positioned above the comb core is raised, moving the hairpins (H) to a position further protruding upward from the comb core (2-2). The upper lifting plate (2-6) is then returned to its starting position adjacent to the comb core (2-2) after the clamping element (2-12) is driven to clamp the hairpin (H), so that the hairpin (H) remains in a position protruding upward from the comb core (2-2) so that the group of hairpins (H) can be picked up and separated from the comb core (2-2) as a whole.

Description

Technical Field

[0001] The present invention generally refers to systems and methods for the manufacture of motor stators, and in particular to a comb device for accommodating a group of hairpins that are to be later moved into the slots of a motor stator.

Background Art

[0002] According to conventional techniques, during the manufacture of a motor stator, the stator winding is obtained by providing flat wires in the form of hairpins that are manually inserted into the slots of the stator core. Due to the large number and variety of hairpins, when an operator repeatedly performs this operation, it is inevitable that the operator may be distracted and misplace the hairpins, thus resulting in an error in the position of the stator winding. As a result, the motor stator cannot be used and needs to be reprocessed, greatly reducing the production efficiency.

[0003] Various solutions have been proposed to automatically perform the operation of inserting hairpins into the slots of a motor stator, but it has been found that none of them are completely satisfactory.

[0004] In document EP 3 868 006 B1, on which the preamble of claim 1 is based, a method for manufacturing a motor stator is proposed, where a stator core template is provided. The hairpins are inserted into the slots of the template to form a complete nest of hairpins, which is then moved into the slots of the "actual" stator core. While inserting the hairpins into the slots of the template, the group of hairpins is inserted into a first position within the slot and then radially inwardly moved towards their final target position by a pusher. However, in this solution, the above-mentioned pusher may engage with the portion of the hairpin that protrudes outward from the template, thereby undesirably deforming the hairpin.

[0005] Therefore, a completely satisfactory solution in this area is still needed.

[0006] [Purpose of the invention] The objective of the present invention is to solve the problems described above by enabling the automatic manufacture of motor stators with high production efficiency while ensuring high precision and quality. [Overview of the project]

[0007] In view of achieving the objectives described above, the present invention relates to a comb device for housing a group of hairpins to be subsequently moved into the slots of a motor stator, the comb device comprising a cylindrical comb core having cylindrical sides and two opposing end faces and a circumferential array of uniformly distributed axial slots, the axial slots opening at their two opposing ends on the two opposing end faces of the comb core, and the slots configured to house a plurality of hairpins, in the comb device, The comb device is characterized in that the axial slot of the comb core also opens radially outward in the aperture on the side surface of the comb core, and the comb device is A circumferential array of clamping elements mounted radially slidably within the slots of the comb core through the aperture on the side surface of the comb core, the clamping elements being configured to clamp the hairpins within the slots after all the hairpins have been positioned within the slots, and A drive mechanism for simultaneously driving the radial motion of all clamp elements within each of the slots of the comb core. It is further characterized by having the following features.

[0008] In a preferred embodiment, the drive mechanism for simultaneously driving the radial motion of all the clamp elements is: A circumferential array of radial drive members surrounds the array of clamping elements outside the comb core, each drive member being operably connected to each of the clamping elements, and the drive members being guided radially slidably within the radial guide passage of a fixed annular plate. A drive annular plate surrounding the comb core and mounted on the fixed annular plate so as to be rotatable around the main axis of the comb core, The drive annular plate includes a plurality of helical slits engaged by a cam follower held by the drive member, the helical slits being configured such that the drive member, and therefore the clamping element, moves radially between the two end positions as the drive annular plate rotates between the two end positions, and An actuator for rotating the drive annular plate between the two end positions. It holds.

[0009] In a preferred embodiment, the helical slit is configured such that the clamping element moves radially at a constant speed as the drive annular plate rotates at a constant speed.

[0010] Furthermore, in a preferred embodiment, each helical slit is engaged by two cam followers held by two adjacent drive members, and therefore the number of helical slits is half the number of clamping elements.

[0011] A more preferred feature is that each drive member is a rod-shaped member having one end hinged to the respective clamp element and the opposite end holding the respective cam follower.

[0012] A more preferred feature is that the comb device comprises an upper lifting plate positioned on the upper end face of the comb core and having a circumferential array of slots corresponding in number and position to the slots of the comb core, so that when a hairpin is inserted axially into the slot of the comb core, the hairpin first engages with the slot of the upper lifting plate and then with the slot of the comb core. The upper lifting plate is connected to an actuator, and the actuator is -When all the hairpins are positioned within the comb core, the upper lifting plate is raised from a position adjacent to the comb core to a raised position spaced upward from the comb core, causing the hairpins to protrude further upward from the upper end face of the comb core. - After the clamping element is driven to clamp the hairpin within the comb core, the upper lifting plate is subsequently returned to its starting position adjacent to the comb core, so that the hairpin remains in the position protruding upward from the comb core, allowing the group of hairpins to be picked up and separated from the comb core as a whole. It is capable of operating in this manner.

[0013] According to further features, the drive mechanism is operable to gradually move the clamp element radially outward while the hairpin is inserted into the slot of the comb core during insertion of the hairpin into the comb core, thereby gradually leaving a wider radial space within the slot for the hairpin to be positioned within the slot.

[0014] The present invention also relates to a method for obtaining a group of hairpins (H) to be moved into the slots of a motor stator, which are implemented using the comb device described above. [Brief explanation of the drawing]

[0015] [Figure 1] Perspective view of a comb device according to the present invention and a system including a robot for inserting hairpins into the comb device. [Figure 2] Perspective view of the comb device of FIG. 1 with the covering plate removed. [Figure 3] Perspective view of a fixed annular plate having a circumferential array of guide passages with a T-shaped cross-section. [Figure 4] Perspective view of a comb core with a group of hairpins inserted therein, also showing two clamping elements slidable within the slots of the comb core, and two drive members connected to the clamping elements. [Figure 5] Perspective view of a drive annular plate that is part of a drive mechanism for causing radial movement of a clamping element within a slot of a comb core. [Figure 6] Bottom perspective view showing a system for actuating the vertical movement of an upper lifting plate of the comb device of the present invention. [Figure 7] Cross-sectional view in the vertical plane of the unit of FIG. 6. [Figure 8] Perspective view of a comb core forming part of the comb device according to the present invention. [Figure 9] View showing details of a single clamping element with associated drive members at an enlarged scale. [Figure 10] Perspective view of the fixed annular plate of FIG. 3, also showing a drive member slidably guided within the guide passage of the plate. [Figure 11] Partial perspective view of the comb device with the covering plate removed. [Figure 12] View showing details of the annular drive plate at an enlarged scale. [Figure 13] Perspective view of the upper part of the comb device with a group of hairpins inserted therein. [Figure 13A] View showing different stages of a process for inserting hairpins. [Figure 13B]A diagram showing different stages of the process for inserting hairpins. [Figure 13C] A diagram showing different stages of the process for inserting hairpins. [Figure 13D] A diagram showing different stages of the process for inserting hairpins. [Figure 14] A diagram showing three mutually different stages of an operation for moving the entire group of hairpins to a position where they further protrude upward from the comb device of the present invention after their insertion. [Figure 15] A diagram showing three mutually different stages of an operation for moving the entire group of hairpins to a position where they further protrude upward from the comb device of the present invention after their insertion. [Figure 16] A diagram showing three mutually different stages of an operation for moving the entire group of hairpins to a position where they further protrude upward from the comb device of the present invention after their insertion.

Embodiments for Carrying Out the Invention

[0016] In FIG. 1, reference numeral 2 generally shows an example of a comb device according to the present invention. The comb device 2 includes a cylindrical comb core 2-2, which is better shown in FIG. 8 and has a slot 2-23 for accommodating a group of hairpins H.

[0017] FIG. 1 shows one hairpin H held by a gripping portion 1-2 of a robot 1-1, which is used to automatically insert the hairpin H into a slot 2-23 (FIG. 8) of the comb core 2-2 of the comb device 2. Using the comb device of the present invention, it becomes possible to automatically insert a complete group of hairpins into the slot of the comb core, and then the complete group of hairpins can be moved from the comb core into the slot of the motor stator.

[0018] As shown in detail in Figure 8, the cylindrical comb core 2-2 has a cylindrical side surface 2-21 and two opposing end faces 2-22. The comb core 2-2 has a circumferential array of uniformly distributed axial slots 2-23 that extend axially from one end face 2-22 to the other, and thus the slots open at the two opposing ends of the comb core 2-2.

[0019] Slot 2-23 also opens radially outward in aperture 2-24 on the outer surface 2-21 of the comb core.

[0020] Returning to Figure 1, each hairpin has a generally U-shaped configuration with two legs and an upper bridge portion. The hairpins H are inserted into slots 2-23 of the comb core 2-2 with their legs oriented downwards.

[0021] In a preferred embodiment, the hairpin H is of a type defined by a wire having a flat, non-circular cross-section.

[0022] Referring to Figure 2, the example of the comb device shown therein includes a fixed frame 2-0 that holds a fixed plate 2-1, and the comb core 2-2 is locked in place on the fixed plate 2-1 by any known means (see also Figure 7). The fixed plate 2-1, as better shown in Figures 3 and 10, holds an annular fixed plate 2-4 surrounding the comb core 2-2, using a plurality of support parts 2-3.

[0023] The comb device of the present invention further includes a circumferential array of clamping elements 2-12 mounted radially slidably within slots 2-23 of the comb core 2-2 through apertures 2-24 on the side surfaces 2-21 of the comb core. In the illustrated example, the comb core has 48 slots 2-23, and therefore 48 clamping elements 2-12 are provided, each clamping element 2-12 being radially slidable within its respective slot 2-23 through the openings 2-24.

[0024] Figure 9 of the drawing shows details of a single clamp element 2-12 at an enlarged scale. Each slot 2-23 (Figure 8) of the comb core 2-2 is formed using a rectangular cross-section defined by two parallel lateral surfaces. Correspondingly, each clamp element 2-12 takes the form of a vertical plate that is slidably mounted between the two lateral surfaces of each slot 2-23, and the vertical dimension of each clamp element 2-12 is smaller than the vertical dimension of the opening 2-24 of the slot 2-23 on the side surface 2-21 of the comb core 2-2.

[0025] As shown in detail in Figure 9, each clamp element 2-12 is driven by a drive member 2-9 in the form of a rod member having an inverted T-shaped cross-section.

[0026] Each drive rod member 2-9 has one end hinged to its respective clamp element 2-12 around a vertical axis at 2-11, and the other end holding a cam follower 2-10 in the form of a freely rotatable roller, the function of which will become clearer below.

[0027] The drive rod member 2-9 associated with the clamp element 2-12 is guided radially within the radial guide passage 2-41 of the fixed annular plate 2-4 (see Figures 3 and 10).

[0028] In the illustrated example, the fixed annular plate 2-4 has a protruding periphery for rotatably supporting the annular drive plate 2-8 (see Figure 5) on the fixed annular plate 2-4.

[0029] As shown in Figures 11 and 12, the drive annular plate 2-8 has a plurality of helical slits 2-81 that are engaged by their respective cam followers 2-10, each held by a respective drive member 2-9.

[0030] In the illustrated example, each helical slit 2-81 is engaged by two cam followers 2-10, which are held by two adjacent drive members 2-9 that are operably connected to two respective clamp elements 2-12.

[0031] The helical slit 2-81 is configured such that each clamp element 2-12 moves radially between two end positions as the drive plate 2-8 rotates between the two end positions. Most preferably, the helical slit 2-81 is configured such that the clamp elements 2-12 move radially at a constant speed as the drive plate 2-8 rotates at a constant speed.

[0032] As shown, each helical slit 2-81 is engaged by two cam followers 2-10. Therefore, the number of helical slits 2-81 is half the number of clamping elements 2-12. Thus, in the case of a comb core with 48 slots, 48 ​​clamping elements 2-12 are provided, while only 24 helical slits 2-81 are provided within the drive plate 2-8. With the configuration shown above, the two drive members 2-9 that hold the cam followers 2-10 engaged within the same helical slit 2-81 have different lengths from each other.

[0033] As can be understood, the preferred configuration shown above makes it possible to manufacture the drive plate 2-8 in a simpler configuration.

[0034] In the illustrated example, the rotation of the annular drive plate 2-8 is controlled by a motor 2-5 held by a fixed base plate 2-1. The motor 2-5 controls the rotation of a crank 2-51 that holds a roller 2-7 which is engaged in a slot 2-82 of the radially extending portion 2-83 of the drive annular plate 2-8.

[0035] In the illustrated example, the comb device of the present invention further includes an upper lifting plate 2-6 positioned on the upper end face of a comb core 2-2 and having a circumferential array of radial slots 2-61 (Figure 13) corresponding in number and position to the slots 2-23 of the comb core 2-2, so that when hairpins H are inserted axially into the slots 2-23 of the comb core 2-2, they first engage with the slots 2-61 of the upper lifting plate 2-6 from above, and then engage with the slots 2-23 of the comb core 2-2.

[0036] The upper lifting plate 2-6 is operably connected to the stem 2-14 of the cylinder 2-13. Referring to Figures 6 and 7, the cylinder 2-13 is positioned vertically below the fixed plate 2-1 along the axis of the comb core 2-2. The body of the cylinder 2-13 is held by a plate 2-131, which is supported by a connecting rod 2-16 fixed to the lower end face of the comb core 2-2. The cylinder 2-13 has a stem 2-14 with an upper end connected to the central portion of the lifting upper plate 2-6. Furthermore, the upper plate 2-6 is connected to a guide rod 2-15 (Figure 6), which is slidably guided through a passage 2-25 (Figure 8) in the comb core 2-2.

[0037] Referring to Figure 1, the dustproof covering plate 2-17 is fixed on the upper peripheral edge 2-42 of the fixed plate 2-4. The peripheral edge 2-42 is interrupted in portion 2-43 (Figure 3) to leave space for the radially extending portion 2-83 of the drive plate 2-8.

[0038] During operation, while the hairpin H is inserted through slot 2-61 of the upper plate 2-6 and through slot 2-23 of the comb core 2-2, the upper plate 2-6 is in the lower position shown in Figure 14, adjacent to the upper end face of the comb core 2-2.

[0039] Figures 13A to 13D show the different stages of the hairpin insertion process. Figure 13A shows the initial stage in which the first set of hairpins H are inserted into the slots, with clamp elements 2-12 positioned in their innermost radial positions. After inserting this first set of hairpins, clamp elements 2-12 are moved slightly radially outward to leave a radial space in each slot that is slightly larger than the radial dimension of the two wires (see Figures 13B and 13C), so that the second wire H2 can be introduced radially outward of the previously inserted first wire H1. The clamp elements are then gradually moved radially outward to allow a total of six wires H1, H2, H3, H4, H5, and H6 (in this example) to be accommodated in each slot (see Figure 13D).

[0040] Once all the hairpins are inserted, they are first pressed downward by a pressing plate (not shown in the drawing) to ensure that all the upper ends of the hairpins are at the same height. In this stage, the upper lifting plate 2-6 is moved with the help of the cylinder 2-13 from the lowered position in Figure 14 to the raised position shown in Figure 15. In this way, the upper lifting plate 2-6 moves all the hairpins H axially upward relative to the comb core 2-2, bringing them to a position where they protrude further upward from the comb core. After this stage, the drive plate 2-8 is rotated by operating the motor 2-5 to move the clamping element 2-15 radially inward, thereby gently pressing the hairpins H against the radially inward end face of the slot 2-23. With the hairpin H clamped in this manner, the upper lifting plate 2-6 is then returned to its lowered position adjacent to the upper end face of the comb core 2-2, as shown in Figure 16, while the hairpin is forced to remain in the same position relative to the comb core 2-2. In this way, the group of hairpins H is positioned to protrude upward from the comb core, where it can be easily picked up and moved to a subsequent station, where the group of hairpins is inserted into a slot in the motor stator.

[0041] Naturally, while the principles of the present invention remain the same, the details of the configuration and embodiments may vary broadly from those described and shown merely as examples, without departing from the scope of the invention as defined in the appended claims.

Claims

1. A comb device for housing a group of hairpins to be subsequently moved into slots of a motor stator, the comb device comprising a cylindrical comb core having cylindrical sides and two opposing end faces and a circumferential array of uniformly distributed axial slots, the axial slots opening at the two opposing ends on the two opposing end faces of the cylindrical comb core, and the slots configured to house a plurality of hairpins therein, The axial slot of the cylindrical comb core also opens radially outward in the aperture of the cylindrical side surface of the cylindrical comb core. The aforementioned comb device, A circumferential array of clamping elements mounted radially slidably within the slots of the cylindrical comb core through the aperture on the cylindrical side surface of the cylindrical comb core, the clamping elements being configured to clamp the hairpins within the slots after all the hairpins have been positioned within the slots, and A drive mechanism for simultaneously driving the radial motion of all clamp elements within each of the slots of the cylindrical comb core. A comb device that further enhances this feature.

2. The drive mechanism for simultaneously driving the radial motion of all the clamp elements is: A circumferential array of radial drive members surrounds the circumferential array of clamping elements outside the cylindrical comb core, each radial drive member being operably connected to each of the clamping elements, and the radial drive members being guided radially slidably within the radial guide passage of a fixed annular plate. A drive annular plate surrounds the cylindrical comb core and is mounted on the fixed annular plate so as to be rotatable around the main axis of the cylindrical comb core, The drive annular plate includes a plurality of helical slits engaged by a cam follower held by the radial drive member, the plurality of helical slits are configured such that the rotation of the drive annular plate between two end positions causes the radial drive member, and therefore the clamping element, to move radially between the two end positions, and An actuator for rotating the drive annular plate between the two end positions. The comb device according to claim 1, having the following:

3. The comb device according to claim 2, wherein the plurality of helical slits are configured such that the clamping element moves radially at a constant speed as the drive annular plate rotates at a constant speed.

4. The comb device according to claim 2, wherein each helical slit is engaged by two cam followers held by two adjacent radial drive members, and therefore the number of helical slits is half the number of clamping elements.

5. The comb device according to claim 2, wherein each radial drive member is a rod-shaped member having one end hinged to the respective clamp element and the opposite end holding the respective cam follower.

6. The comb device according to claim 2, wherein each radial drive member is a rod-shaped member having a T-shaped cross-section and is slidably guided within the respective radial guide passages of the fixed annular plate having a corresponding T-shaped cross-section.

7. The comb device further comprises an upper lifting plate positioned on the upper end face of the cylindrical comb core and having a circumferential array of slots corresponding in number and position to the slots of the cylindrical comb core, so that when a hairpin is inserted axially into the slot of the cylindrical comb core, the hairpin first engages with the slot of the upper lifting plate and then engages with the slot of the cylindrical comb core, The upper lifting plate is connected to an actuator, and the actuator is - Once all the hairpins are positioned within the cylindrical comb core, the upper lifting plate is raised from a position adjacent to the cylindrical comb core to an elevated position spaced upward from the cylindrical comb core, causing the hairpins to protrude further upward from the upper end face of the cylindrical comb core. - After the clamping element is driven to clamp the hairpin within the cylindrical comb core, the upper lifting plate is subsequently returned to its starting position adjacent to the cylindrical comb core, so that the hairpin remains in the position protruding upward from the cylindrical comb core, allowing the group of hairpins to be picked up and separated from the cylindrical comb core as a whole. A comb device according to any one of claims 1 to 6, which is operable in such a way.

8. The comb device according to any one of claims 1 to 6, wherein the drive mechanism is operable to gradually move the clamping element radially outward while the hairpin is inserted into the slot of the cylindrical comb core, thereby gradually leaving a wider radial space within the slot for the hairpin to be positioned within the slot.

9. A method for obtaining a group of hairpins to be moved into a slot of a motor stator, A step of providing a comb device including a cylindrical comb core having cylindrical sides and two opposing end faces, and a circumferential array of uniformly distributed axial slots, wherein the axial slots are open at the two opposing ends on the two opposing end faces of the cylindrical comb core, and The step of inserting multiple hairpins into the slots of the cylindrical comb core. In a method that provides, The axial slot of the cylindrical comb core also opens radially outward in the aperture of the cylindrical side surface of the cylindrical comb core. The aforementioned comb device, A circumferential array of clamping elements mounted radially slidably within the slot of the cylindrical comb core through the aperture on the cylindrical side surface of the cylindrical comb core, A drive mechanism for simultaneously driving the radial motion of all clamp elements within each of the slots of the cylindrical comb core, It further includes, The above method is a step of operating the drive mechanism to move the clamp element in the slot. A method that includes [a certain feature].

10. The method according to claim 9, wherein the drive mechanism is operated to gradually move the clamping element radially outward while the hairpin is inserted into the slot of the cylindrical comb core, thereby gradually leaving a wider radial space within the slot for the hairpin to be positioned within the slot.

11. The aforementioned method, - Providing an upper lifting plate positioned on the upper end face of the cylindrical comb core and including a circumferential array of slots corresponding in number and position to the slots of the cylindrical comb core, so that when a hairpin is inserted axially into the slot of the cylindrical comb core, the hairpin first engages with the slot of the upper lifting plate, and then engages with the slot of the cylindrical comb core, and the upper lifting plate is connected to an actuator. - Once all the hairpins are positioned within the cylindrical comb core, the actuator is used to raise the upper lifting plate from a position adjacent to the cylindrical comb core to a raised position spaced upward from the cylindrical comb core, such that the upper lifting plate causes the hairpins to protrude further upward from the upper end face of the cylindrical comb core, and - After the clamping element is driven to clamp the hairpin within the cylindrical comb core, the actuator is used to subsequently return the upper lifting plate to its starting position adjacent to the cylindrical comb core, so that the hairpin remains in the position protruding upward from the cylindrical comb core, allowing the group of hairpins to be picked up and separated from the cylindrical comb core as a whole. The method according to claim 9 or 10, further comprising:

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