Automatic wire insertion process for rectangular wire stator

Abstract

To provide an automatic wire insertion process for a rectangular wire (a type of a wire with a rectangular cross section) stator with a fast wire insertion speed.SOLUTION: A method includes the steps of arranging copper wires on a plurality of wire arranging tools in sequence on the basis of the number of layers and the number of grooves of different stator winding structures, sequentially feeding the plurality of wire arranging tools on which the copper wires are arranged to a wire winding mechanism, sequentially winding the copper wires arranged on the wire arranging tools onto a winding assembly by the wire winding mechanism, and then forming a predetermined winding structure, and transferring and inserting the predetermined winding structure into the interior of the stator.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to the technical field of automatic wire insertion into a stator, and more particularly to an automatic wire insertion process for a rectangular wire stator. [Background technology]

[0002] Hairpin permanent magnetic synchronous motors are gradually being applied on a large scale in the Chinese drive motor market. Compared to traditional wound motors, the flatness of the hairpin copper wire allows for a smaller motor volume and higher power efficiency under the same power, making them the development direction for the next generation of new energy drive motors. However, due to the complex manufacturing process and difficult product design, there is currently no mature mass production line in the Chinese market.

[0003] During the motor production process, different copper wires need to be inserted into the stator to form the stator winding. However, when inserting the copper wires, in many cases, the wires are inserted one by one into the wire grooves of the stator using a wire insertion device, and the copper wires are not first aligned using a wire alignment tool as needed. Instead, the copper wires are wound by a winding mechanism and then inserted all at once. This slows down the wire insertion speed of the copper wires, which affects the production efficiency of the motor. Summary of the Invention [Problem to be solved by the invention]

[0004] SUMMARY OF THE INVENTION The objective of the present invention is to provide an automatic wire insertion process for rectangular wire (a type of wire with a rectangular cross section) stator with a fast wire insertion speed, in order to overcome the deficiencies of the prior art. [Means for solving the problem]

[0005] The technical solution of the present invention is as follows:

[0006] An automatic wire insertion process for a rectangular wire stator, Step S1: arranging copper wires in a plurality of wire arranging tools in order based on the number of layers and the number of grooves of different stator winding structures; Step S2: sequentially sending the plurality of wire arranging tools on which the copper wires are arranged to a wire winding mechanism; Step S3 in which the wire winding mechanism sequentially winds the copper wires arranged on the wire arranging tool onto the winding assembly to form a predetermined winding structure; and step S4 of transferring and inserting the predetermined winding structure into the interior of the stator.

[0007] Furthermore, when the stator winding has 6 layers and 48 grooves, the copper wire arrangement is as follows: S1: Three A copper wires and three B copper wires are alternately arranged from right to left on a wire arrangement tool with one turn, and the spacers between two straight sections of the A copper wires are six core grooves, among which the spacers between two straight sections of the B copper wires are four core grooves; S2: 36 C copper wires are stacked on the single-wound wire arrangement tool in the arrangement order from left to right, and the wire arrangement of the single-wound wire arrangement tool is completed; S3: 12 D copper wires are stacked on the two-wound wire arrangement tool in order from right to left, and after completing the arrangement of the D copper wires, 36 E copper wires are stacked on the two-wound wire arrangement tool in order from left to right, and the arrangement of the two-wound wire arrangement tool is completed; S4: According to the arrangement method of the D copper wire and the E copper wire, the F copper wire and the G copper wire are arranged on a wire arrangement tool with three turns, and the number of the G copper wires is the same as the number of the C copper wires; S5: Arrange the 12 H copper wires one by one on the wire arrangement tool with three windings, and complete the wire arrangement on the wire arrangement tool with three windings.

[0008] Furthermore, copper wire A, copper wire B, copper wire C, copper wire D, copper wire E, copper wire F and copper wire G are all U-shaped hairpin copper wires, and copper wire H is an I-shaped copper wire.

[0009] Furthermore, when the stator winding has six layers and 48 grooves, when the wire winding mechanism winds one turn, the A copper wire is wound from the first groove of the first layer of the stator and stops in the twelfth groove of the first layer, and the B copper wire is wound from the second groove of the first layer and stops in the eleventh groove of the first layer, and the A copper wire and the B copper wire do not overlap.

[0010] Furthermore, the C copper wire is wound from the 13th groove of the first layer of the stator, and the C copper wires located in the 19th groove to the 48th groove are overlapped, and the overlapped C copper wires are respectively located in the first and second layers of the stator, and the C copper wires located in the 1st groove to the 6th groove are installed in the second layer of the stator.

[0011] Furthermore, when the winding mechanism winds twice, the D copper wire is wound from the first slot of the third layer of the stator, the D copper wires located in the seventh slot to the twelfth slot are overlapped, and the overlapped D copper wires are located on the second and third layers of the stator, and the D copper wires located in the thirteenth slot to the eighteenth slot are installed on the second layer of the stator.

[0012] Furthermore, the E copper wire is wound from the 13th groove of the third layer, and the E copper wires located in the 19th groove to the 48th groove are overlapped, and the overlapped E copper wires are respectively located in the third and fourth layers of the stator, and the E copper wires located in the 1st groove to the 6th groove are installed in the fourth layer of the stator.

[0013] Furthermore, when the winding mechanism winds three times, the F copper wire is wound from the first slot of the fifth layer of the stator, the F copper wires located in the seventh slot to the twelfth slot are overlapped, and the overlapped F copper wires are located on the fourth and fifth layers of the stator, and the F copper wires located in the thirteenth slot to the eighteenth slot are installed on the fourth layer of the stator.

[0014] Furthermore, the G copper wire is wound from the 13th groove of the 5th layer and stops in the 6th groove of the 6th layer, the G copper wires located in the 19th groove to the 48th groove are overlapped, and the overlapped G copper wires are respectively located on the 5th and 6th layers of the stator, the G copper wires located in the 1st groove to the 6th groove are installed on the 6th layer of the stator, and the H copper wire is wound from the 7th groove of the 6th layer and stops in the 18th groove of the 6th layer.

[0015] Furthermore, the wire winding mechanism includes a wire arranging tool for arranging the flat copper wires, a winding mechanism for winding the arranged flat copper wires, a flat copper wire transport mechanism, and a tool transport mechanism, which are installed in the stator winding device; the tool transport mechanism is used to transport the wire arranging tool to a winding mechanism; The flat copper wire transport mechanism is used to transport the flat copper wires arranged on the wire arranging tool, which has been transported to the winding mechanism, to the winding mechanism and wind them. [Effects of the Invention]

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0017] 1. The present invention arranges copper wires according to different stator winding structures, and uses a wire winding mechanism to achieve winding formation of a predetermined winding structure, making it easier to form the stator winding; 2. The present invention arranges copper wire A, copper wire B, copper wire C, copper wire D, copper wire E, copper wire F, copper wire G, and copper wire H in three layers, and winds them into a predetermined winding by a winding mechanism, and inserts the predetermined winding into the stator, thereby realizing automatic wire insertion; As can be seen, the present invention has the advantage of accelerating wire insertion speed. [Brief explanation of the drawings]

[0018] [Figure 1] FIG. 10 is a diagram showing the winding structure after the first wire winding of the present invention. [Figure 2] FIG. 10 is a diagram showing the winding structure after the second wire winding of the present invention. [Figure 3] FIG. 10 is a diagram showing the winding structure after the third wire winding of the present invention. [Figure 4] FIG. 2 is a structural diagram of the present invention after molding. [Figure 5] FIG. 1 is a schematic diagram of the position of the winding after the first wire winding of the present invention. [Figure 6] FIG. 10 is a schematic diagram of the position of the winding after the second wire winding of the present invention. [Figure 7] FIG. 10 is a schematic diagram of the position of the winding after the third wire winding of the present invention. [Figure 8] 1 is a schematic diagram of a copper wire structure of the present invention. [Figure 9] 1 is a structural schematic diagram of a line aligning tool of the present invention; [Figure 10] 1 is a perspective schematic view of the structure of the present invention; [Figure 11] 1 is a perspective schematic view of a combined state of a wire passing portion and a wire guide portion according to the present invention; [Figure 12] 1 is a perspective schematic view of the tool, wire winding section, wire movement assembly, and wire guide block of the present invention in combination; FIG. [Figure 13] FIG. 2 is a schematic perspective view of a wire winding portion according to the present invention. [Figure 14] 1 is a perspective schematic view of a wire clamp assembly according to the present invention; [Figure 15] 1 is a perspective schematic view of a combination of a winding assembly and a cover plate according to the present invention; [Figure 16] 1 is a perspective schematic view of an umbrella-shaped member, an insertion sheet, and a bush in a separated state according to the present invention; [Figure 17] 1 is a perspective partial cross-sectional schematic view of a locking assembly according to the present invention; [Figure 18] FIG. 2 is a perspective schematic view of a jack-up unit according to the present invention. [Figure 19] FIG. 2 is a schematic perspective view of a positioning portion according to the present invention. [Figure 20] 1 is a perspective schematic view of a separation structure of a hollow reducer, a bush, and a servo motor according to the present invention. FIG. [Figure 21] 1 is a schematic diagram of a single turn wire aligning tool of the present invention. [Figure 22] FIG. 1 is a schematic diagram of a two-turn wire aligning tool of the present invention. [Figure 23] FIG. 1 is a schematic diagram of a three-turn wire aligning tool of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0019] The following clearly and completely describes the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only some embodiments of the present invention, not all embodiments, and all other embodiments obtained by those skilled in the art based on the embodiments of the present invention without any creative efforts are all within the protection scope of the present invention.

[0020] As shown in Figure 1-23, the automatic wire insertion process for rectangular wire stator is as follows: Step S1: Arranging copper wires in a plurality of wire arranging tools (2) in order based on the number of layers and the number of grooves of different stator winding structures; Step S2: sequentially sending the plurality of wire arranging tools on which the copper wires are arranged to a wire winding mechanism; Step S3 in which the wire winding mechanism sequentially winds the copper wires arranged on the wire arranging tool onto the winding assembly to form a predetermined winding structure; and step S4 of transferring and inserting the predetermined winding structure into the interior of the stator.

[0021] In this embodiment, when the stator winding has 6 layers and 48 grooves, the copper wire arrangement is as follows: S1: Three A copper wires and three B copper wires are alternately arranged from right to left on a wire arrangement tool 2 with one winding, and the spacers between two straight sections of the A copper wire are six core grooves, among which the spacers between two straight sections of the B copper wire are four core grooves; S2: 36 C copper wires are stacked on the one-turn wire arrangement tool 2 in the arrangement order from left to right, and the one-turn wire arrangement tool 2 is completed; S3: 12 D copper wires are stacked on the wire arrangement tool 2 with two windings in order from right to left, and after completing the arrangement of the D copper wires, 36 E copper wires are stacked on the wire arrangement tool 2 with two windings in order from left to right, and the wire arrangement of the wire arrangement tool 2 with two windings is completed; S4: According to the arrangement method of the D copper wire and the E copper wire, the F copper wire and the G copper wire are arranged on the wire arrangement tool 2 with three turns, and the number of the G copper wires is the same as the number of the C copper wires; S5: Arrange the 12 H copper wires one by one on the wire arrangement tool 2 with three windings, and complete the wire arrangement on the wire arrangement tool 2 with three windings.

[0022] In this embodiment, copper wires A, B, C, D, E, F and G are all U-shaped hairpin copper wires 101, and copper wire H is an I-shaped copper wire 102.

[0023] In this embodiment, 48 grooves are used as an example. When the winding mechanism winds copper wire A, copper wire B, and copper wire C once, copper wire A is wound from the first slot of the first layer of the stator and stops in the twelfth slot of the first layer, and copper wire B is wound from the second slot of the first layer and stops in the eleventh slot of the first layer, and copper wire A and copper wire B do not overlap.

[0024] The C copper wire is wound from the 13th groove of the first layer of the stator, and the C copper wires located in the 19th groove to the 48th groove are overlapped, and the overlapped C copper wires are respectively located in the first and second layers of the stator, and the C copper wires located in the 1st groove to the 6th groove are installed on the second layer of the stator.

[0025] When the winding mechanism winds twice, the D copper wire is wound from the first slot of the third layer of the stator, the D copper wires located in the seventh slot to the twelfth slot are overlapped, and the overlapped D copper wires are located on the second and third layers of the stator, and the D copper wires located in the thirteenth slot to the eighteenth slot are installed on the second layer of the stator.

[0026] The E copper wire is wound from the 13th slot on the third layer, and the E copper wires located in the 19th to 48th slots overlap each other, and the overlapped E copper wires are located on the third and fourth layers of the stator, respectively. The E copper wires located in the 1st to 6th slots are installed on the fourth layer of the stator.

[0027] When the winding mechanism winds three times, the F copper wire is wound from the first slot of the fifth layer of the stator, the F copper wires located in the seventh slot to the twelfth slot are overlapped, and the overlapped F copper wires are located on the fourth and fifth layers of the stator, and the F copper wires located in the thirteenth slot to the eighteenth slot are installed on the fourth layer of the stator.

[0028] The G copper wire is wound from the 13th groove of the 5th layer and stops in the 6th groove of the 6th layer; the G copper wires located in the 19th groove to the 48th groove are overlapped, and the overlapped G copper wires are located on the 5th and 6th layers of the stator, respectively; the G copper wires located in the 1st groove to the 6th groove are installed on the 6th layer of the stator; and the H copper wire is wound from the 7th groove of the 6th layer and stops in the 18th groove of the 6th layer.

[0029] In this embodiment, the wire arranging tool 3 has wire grooves formed therein, and the wire grooves and the stator core grooves are equidistant from each other.

[0030] In this embodiment, as shown in FIGS. 10-20 , the tool transport mechanism includes a wire arranging tool 2 for arranging flat copper wires, a winding mechanism for winding the arranged flat copper wires, a flat copper wire transport mechanism, and a tool transport mechanism, which are installed in the stator winding device. The tool transport mechanism is used to transport the wire arranging tool 2 to the winding mechanism, the winding mechanism is installed on the fixed frame 10, and the tool transport mechanism is installed below the winding mechanism; The flat copper wire conveying mechanism is used to transport the flat copper wires arranged on the wire arranging tool 2 that have been transported to the winding mechanism and wind them. The flat copper wire conveying mechanism is installed on a fixed frame 10 and is distributed on both sides of the winding mechanism.

[0031] In this embodiment, the tool transport mechanism and the flat copper wire transport mechanism are fitted together to transport the aligned flat copper wires to the winding mechanism and wind them.

[0032] Specifically, as shown in FIG. 10, the tool transport mechanism includes a line 1 for transporting a wire arranging tool 2, which includes a wire arranging plate and a support plate assembly. The wire arranging plate is located on the support plate assembly, and adjustment assemblies are installed on both sides of the support plate assembly. The adjustment assemblies can press the support plate assembly into contact with the flat copper wire on the wire arranging plate, aligning the flat copper wire. In use, flat copper wires of different specifications can be arranged on the wire arranging plate according to the winding requirements. The adjustment assembly presses the support plate assembly into contact with the flat copper wire on the wire arranging plate until both ends of the flat copper wire are aligned, and then the adjustment assembly resets, and the support plate assembly resets and no longer contacts the flat copper wire, facilitating subsequent winding. A sliding belt is installed on the line 1, and the support plate assembly is located on the sliding belt. The sliding belt is driven by a drive mechanism, thereby moving the entire wire arranging tool 2.

[0033] Specifically, as shown in FIG. 10, the flat copper wire conveying mechanism includes a wire passing section 3 that can slide in the left-right direction and conveys the flat copper wire in the wire arranging tool 2 to the winding mechanism, and a wire guide section 4 that can slide in the left-right direction and prevents the flat copper wire wound by the winding mechanism from falling off. The wire passing section 3 and the wire guide section 4 are distributed on fixed frames 10 on both sides of the winding mechanism. The wire passing section 3 includes a wire moving assembly 33 that conveys the flat copper wire in the wire arranging tool 2 to the winding mechanism. The wire moving assembly 33 is driven by a first driving assembly to move up and down. As shown in FIG. 11, the wire passing section 3 includes a first mounting base 30, a first cylinder 31, a first driving assembly, and a wire moving assembly 33, and the first driving assembly is a second cylinder 32. The first mounting base 30 is a right-angle plate divided into a vertical plate and a horizontal plate. The horizontal plate is slidably mounted on the fixed frame 10 on both sides of the winding mechanism along the left-right direction. The first cylinder 31 is fixedly connected to the fixed frame 10 located on one side of the wire passing section 3, and the output end of the first cylinder 31 is fixed to the horizontal plate and can be rotated toward or away from the winding mechanism. The vertical plate is installed at the end of the horizontal plate facing the winding mechanism, and a second cylinder 32 with its output end facing downward is fixedly connected to the upper end of the vertical plate. The line moving assembly 33 is fixedly connected to the output end of the second cylinder 32 and is slidably mounted on the vertical plate, ensuring that the line moving assembly 33 is more stable when moving. The second cylinder 32 can adjust the vertical height position of the line moving assembly 33 to match the position of the winding mechanism, facilitating accurate fitting with the winding mechanism. As shown in FIG. 11, the wire guide unit 4 includes a second mounting base 40, a third cylinder 41, a wire guide block 42, and a second driving assembly. The second mounting base 40 is a right-angle plate that matches the shape of the first mounting base 30, and the second driving assembly is a fourth cylinder 43. The installation form of the second mounting base 40, the third cylinder 41, and the fourth cylinder 43 is the same as the installation form of the first mounting base 30, the first cylinder 31, and the second cylinder 32. However, the wire guide unit 4 and the wire passing unit 3 are distributed mirror-symmetrically with respect to the winding mechanism, and there is another difference between them. The wire guide block 42 is fixedly connected to the output end of the second cylinder 32, and the wire guide block The cylinder 42 is slidably mounted on the vertical plate of the second mounting base 40, which is a rectangular plate, to ensure the stability of the wire guide block 42 when sliding. The third cylinder 41 and the fourth cylinder 43 are fitted together to position the wire guide block 42 at the optimum operating position during the operation of the winding mechanism. The function of the wire guide block 42 is to prevent the flat copper wire from falling off when the winding mechanism is winding it. The surface of the wire guide block 42 that fits into the winding mechanism should be an arc-shaped surface with the same arc degree as the rotation locus of the winding mechanism, and the upper end of the arc-shaped surface should be higher than the horizontal plane of the axis of the winding mechanism, so that the arc-shaped surface can be more closely attached to the winding mechanism. As shown in Figures 11 and 12, two sets of wire transfer assemblies 33 are installed, and each set of wire transfer assemblies 33 includes a sliding plate 34, two baffle plates 35, a first motor 36, and a conveyor belt 37. The side of the baffle plate 35 facing the winding mechanism is similarly formed as an arc-shaped surface. The sliding plate 34 is slidably mounted on the vertical plate of the first mounting base 30, which is a rectangular plate. The first motor 36 and conveyor belt 37 are both installed between the two baffle plates 35. The first motor 36 moves the conveyor belt 37 by means of rollers, so that the entire conveyor belt 37 is inclined, with the end of the conveyor belt 37 facing the sliding plate 34 being higher than the other end, and the upper end of the conveyor belt 37 should transition flatly with the arc-shaped surface of the baffle plate 35, thereby better realizing the transportation of rectangular copper wire.

[0034] Specifically, as shown in Figures 12 and 13, the stator winding device further includes a positioning unit 7 for mounting a winding mechanism, and the positioning unit 7 is used to adjust the position of the winding mechanism. The winding mechanism further includes a wire winding unit 5, and the wire winding unit 5 includes a winding assembly 55 for winding the flat copper wire. The wire winding unit 5 is detachably attached to a manipulator. When winding the wire, the manipulator places the wire winding unit 5 in a winding station. After winding the wire, the manipulator directly moves the wire winding unit 5 to a corresponding station in the subsequent flat copper wire processing process. The winding assembly 55 is rotated by a third driving mechanism. The inner and outer diameters of the winding assembly 55 are variable. The winding assembly 55 includes a bushing 57 with a plurality of insertion grooves 53 formed therein, and cover plates are attached to both ends of the bushing 57. are fixedly connected, and an insertion sheet 58 is slidably connected to each insertion groove 53 along the height direction of the insertion groove 53, and the multiple insertion sheets 58 and the insertion grooves 53 are distributed in an annular array, and a space for winding the flat copper wire is formed between every two insertion sheets 58, and at least two umbrella-shaped members 59 are slidably installed in the axial direction of the bushing 57 for sliding the insertion sheet 58, and the umbrella-shaped members 59 are fixed to a rotating shaft 56 that overlaps with the central axis of the bushing 57, and a chute 11 is opened on the side of the insertion sheet 58 facing the rotating shaft 56, which is inclined by a certain angle, and an extension rod that is inserted into the chute 11 is fixedly connected to the end with the larger opening of the umbrella-shaped member 59, and both ends of the rotating shaft 56 are slidably connected to two cover plates, thereby changing the position of the insertion sheet 58 in the insertion groove 53 and further changing the outer diameter formed by the insertion sheet 58, As shown in Figures 12 and 13, the wire winding unit 5 further includes an attachment base 50, a fifth cylinder 51, a fourth drive mechanism 52, a locking assembly 9, and a sliding base 54. The attachment base 50 is controlled by a manipulator to control the attachment and detachment of the wire winding unit 5. The fourth drive mechanism 52 includes a servo motor 12 and a hollow reducer 13. The input shaft of the hollow reducer 13 is fixedly connected to the output shaft of the servo motor 12, and the output end of the hollow reducer 13 is fixed to the cover plate of the winding assembly 55 facing the fifth cylinder 51. This allows the servo motor 12 to rotate the bush 57 via the hollow reducer 13. As shown in Figures 17 and 19, the sliding base 54 is connected to the lower end of the mounting base 50 in a sliding manner along the front-to-rear direction. The locking assembly 9 is installed on the sliding base 54. The locking assembly 9 includes a ninth cylinder 90, a steel ball 91, a rotary joint 92, and a sliding sleeve 93. The fifth cylinder 51 is fixedly mounted on the rear end of the mounting base 50. The output end of the fifth cylinder 51 is fixed to the sliding base 54. The sliding base 54 is connected to the fifth cylinder 51 so as to slide back and forth. The ninth cylinder 90 is fixedly connected to the sliding base 54. A rotary joint 92 is fixedly connected to the center of the sliding base 54. The rotary shaft 56 passes through the cover plate and is rotatably connected to the inner surface of the rotary joint 92. The other end of the rotary shaft 56 is slidably connected to a hollow cylinder. The hollow cylinder is fixed to the inner surface of the cover plate at the end of the bushing 57 that is far from the rotary joint 92, so that the support of the rotary shaft 56 to the winding assembly 55 can be more stabilized. The ninth cylinder 90 is fixedly connected to the sliding base 54. The rotary joint 92 is installed through the sliding base 54, and the sliding sleeve 93 is covered at one end of the rotary joint 92. The end of the sliding sleeve 93 away from the rotary joint 92 is fixed to the output end of the ninth cylinder 90. The rotary shaft 56, the sliding sleeve 93 and the rotary joint 92 have the same axial center. The rotary joint 92 is installed through the sliding base 54, and the sliding sleeve 93 is covered at one end of the rotary joint 92. The rotary shaft 56 is inserted into the other end of the rotary joint 92. At this time, the rotary shaft 56 moves back and forth in the forward and backward directions. The rotary shaft 56 can rotate along with the bushing 57, and the steel ball 91 is movably connected to the side of the rotary joint 92 facing the sliding sleeve 93. The end of the rotary shaft 56 facing the sliding sleeve 93 has an annular groove for the steel ball 91 to roll in. The rear end of the inner surface of the sliding sleeve 93 has a protrusion for pressing the steel ball 91, so that the steel ball 91 passes through the rotary joint 92 and is locked in the annular groove at the end of the rotary shaft 56. With this arrangement, when it is necessary to remove the winding assembly 55, the ninth cylinder 90 is contracted, the sliding sleeve 93 is retracted from the rotary joint 92, and when the rotary shaft 56 is pulled out of the rotary joint 92, most of the rotary joint 92 is pushed into the sliding sleeve 93 via the steel ball 91, thus enabling the winding assembly 55 to be quickly removed.

[0035] Specifically, as shown in FIG. 14 , the winding mechanism further includes a wire clamp assembly 8 for clamping the winding assembly 55 around which the flat copper wire is wound. The wire clamp assembly 8 includes a base 80, first mounting blocks fixedly connected symmetrically to the upper end surface of the mounting base 50, a tenth cylinder 81 hingedly connected to the first mounting block, a first swing arm 83 rotatably connected to both sides of the bottom of the base 80, a second swing arm 84 rotatably connected to the end of the first swing arm 83 away from the base 80, a second mounting block fixedly connected to the second swing arm 84, an eleventh cylinder 82 hingedly connected to the second mounting block, a drive gear 85, a driven gear 86, and a belt 87. The base 80 is installed on the lower end surface of the mounting base 50. The output end of the tenth cylinder 81 is rotatably connected to the first swing arm 83, the drive gear 85 is rotatably installed at the end of the first swing arm 83 away from the base 80, the driven gear 86 is rotatably connected to the hinge connection point between the first swing arm 83 and the second swing arm 84, and the axis of the driven gear 86 is coaxial with the hinge connection point between the first swing arm 83 and the second swing arm 84, the drive gear 85 is installed in mesh with the driven gear 86, and the drive teeth on the surface of the drive gear 85 A connecting post is installed at a point radially away from the center of the wheel 85, and the output end of the 11th cylinder 82 is rotatably connected to the connecting post, and the end of the belt 87 is fixedly connected to the side of the second swing arm 84 opposite the center of the winding assembly 55. When the 10th cylinder 81 and the 11th cylinder 82 drive the first swing arm 83 and the second swing arm 84 to clamp the winding assembly 55, the belt 87 tightly wraps around the outer surface of the winding assembly 55, preventing the flat copper wire from falling off.

[0036] Specifically, as shown in FIG. 18 , the tool transport mechanism further includes a jack-up unit 6 that can slide in the left-right direction and that jacks up the wire arranging tool 2, and is used to accurately transport the flat copper wire in the wire arranging tool 2 to the winding assembly 55 for winding. The jack-up unit 6 includes a bottom frame, slide rails 60 fixedly connected to the bottom frame symmetrically, slide plates 61 slidably connected to the slide rails 60, a horizontal plate 62 that is slidably installed on the slide plate 61 in the up-down direction, a positioning rod 63 fixedly connected to the horizontal plate 62, a rack 64 fixedly connected to the bottom frame, a third motor 65 fixedly connected to the slide plate 61, a first gear 66 fixedly connected to the output shaft of the third motor 65, and a sixth cylinder 67 fixedly connected to the lower end surface of the slide plate 61, and the output shaft of the sixth cylinder 67 passes through the slide plate 61. , is used to slide the horizontal plate 62 upward, the first gear 66 is connected to and meshed with the rack 64, the third motor 65 is used to drive the first gear 66 to rotate, the mutual meshing of the first gear 66 and the rack 64 causes the sliding plate 61 to reciprocate linearly along the sliding rail 60, when the wire arranging tool 2 slides along the line 1 in the direction approaching the wire winding unit 5, the sixth cylinder 67 pushes up the horizontal plate 62, the positioning rod 63 pushes up the wire arranging tool 2 so that it moves away from the line 1, the horizontal plate 62 slides along the sliding rail 60 and approaches the wire winding unit 5, in order to improve operating efficiency, the other jack-up unit 6 can continue to transport the wire arranging tool 2, and the previous jack-up unit 6 continues to receive the new wire arranging tool 2, ensuring the continuity of the winding operation.

[0037] 12, 15 and 16, a fixed plate 70 is fixedly connected to the fixed frame 10 at the front end of the winding assembly 55, a seventh cylinder 71 is fixedly connected to the lower end of the fixed plate 70, the output end of the seventh cylinder 71 passes through the fixed plate 70 and is fixedly connected to a transition plate, and an eighth cylinder 72 is fixedly connected to the transition plate, thereby adjusting the height and front-rear position of the entire wire winding unit 5 so that the wire winding unit 5 can be located at the center of the flat copper wire transport mechanism, and the winding assembly 55 can be better fitted to the arc-shaped surfaces of the wire passing unit 3 and the wire guide unit 4, thereby effectively preventing the flat copper wire from falling off, the output end of the eighth cylinder 72 faces the winding assembly 55 and is fixedly connected to a movable block 73, and the end of the movable block 73 facing the winding assembly 55 is engaged with the cover plate of the bush 57 facing the movable block 73 The alignment block 74 is rotatably connected to the winding assembly 55, and at least two grooves are formed on the side of the alignment block 74 facing the winding assembly 55. The cover plate of the bushing 57 facing the movable block 73 is formed with at least two inserts that correspond to the distribution of the grooves. When the wire winding unit 5 is placed on the fixed frame 10, the seventh cylinder 71 jacks up the fixed plate 70, and the eighth cylinder 72 adjusts the position and height of the alignment block 74. The eighth cylinder 72 then pushes the movable block 73 closer to the wire winding unit 5, causing the grooves to cover the inserts and the alignment block 74 to engage with the cover plate. Thus, the seventh cylinder 71 and the eighth cylinder 72 control the centering adjustment of the wire winding unit 5, ensuring that the wire winding unit 5 is in the correct winding position and ensuring the final winding effect.

[0038] The operating principle of the wire winding mechanism is as follows: First, the manipulator aligns the flat copper wire on the wire arranging tool 2, then the line 1 transports the wire arranging tool 2 to a predetermined position, and then the sixth cylinder 67 extends to lift the wire arranging tool 2. After lifting it to a predetermined position, the third motor 65 starts to rotate the first gear 66, and the rack 64 engages, causing the sliding plate 61 to slide the entire jack-up unit 6 along the sliding rail 60 to the bottom of the winding assembly 55. The positioning unit 7, the wire guide unit 4, and the wire passing unit 3 adjust the position of the winding assembly 55, so that the insertion sheet 58 of the winding assembly 55 can be tightly attached to the arc-shaped surface. Then, the first motor 36 in the wire passing unit 3 starts to operate, and at the same time, the servo motor 12 also starts, causing the conveyor belt 37 to transport the flat copper wire to the winding assembly 55, and the winding assembly 55 winds the flat copper wire, and the arc-shaped surface is set. When the winding assembly 55 has wound one turn, the flat copper wire will not fall off from the gap between the two insertion seats 58. At the same time, the wire clamping assembly 8 is activated, causing the tenth cylinder 81 to extend and rotate the first swing arm 83. At the same time, the eleventh cylinder 82 performs a reciprocating telescopic motion, causing the eleventh cylinder 82 to rotate the driving gear 85, which in turn rotates the driven gear 86, causing the second swing arm 84 to rotate. At the same time, the belt 87 is wound around the outside of the winding assembly 55, further preventing the flat copper wire from falling off. After the clamping operation is completed, the manipulator directly moves the wire winding unit 5 to the wire insertion station in the stator processing process. When the manipulator moves the wire winding unit 5 to the wire insertion station, it releases the wire clamping assembly 8 and inserts the wound flat copper wire into the wire insertion tool at the corresponding wire insertion station. Then, the other manipulator replaces and operates the next wire winding unit 5. When the next wire winding unit 5 is to be replaced, the other manipulator controls the wire winding unit 5 to be inserted into the alignment block 74 toward the insert on one side of the positioning unit 7, thereby completing the installation of the wire winding unit 5. Then, the seventh cylinder 71 and the eighth cylinder 72 adjust the height and the position of the wire winding unit 5 along the front-rear direction, respectively, so as to facilitate the cooperation of the winding assembly 55 with the wire passing unit 3, the wire guide unit 4, the jack-up unit 6 and the wire arranging tool 2. The two manipulators operate alternately, so that the wire winding unit 5 does not need to be replaced frequently. When adjusting the position of the insertion seat 58 in the insertion groove 53, the fifth cylinder 51 is controlled to extend and retract, thereby pushing the sliding base 54 so that it slides along the mounting base 50. The mounting base 50 slides the rotary joint 92, which then slides the rotating shaft 56. The rotating shaft 56 slides the umbrella-shaped member 59, adjusting the length by which the extension rod extends into the chute 11, and further adjusting the position of the insertion seat 58 in the insertion groove 53, thereby changing the outer diameter of the winding assembly 55.

[0039] All the above electronic components are conventional electronic components of the prior art, and the control method is all performed by an industrial computer.

[0040] Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art may modify the technical solutions described in the above embodiments or may equivalently replace some of the technical features thereof, and any modifications, equivalent replacements and improvements made within the spirit and principle of the present invention shall be included in the protection scope of the present invention. [Explanation of symbols]

[0041] 1 line 10 Fixed Frame 11 Shoot 12 Servo motor 13 Hollow reducer 2 Line Arrangement Tool 3 wire passing section 30 First mounting base 31 No. 1 cylinder 32 No. 2 cylinder 33 Line moving assembly 34 Sliding plate 35 Baffle plate 36 First motor 37 Conveyor Belt 4 Wire guide section 40 Second mounting base 41 Third cylinder 42 Wire guide block 43 4th cylinder 5 Wire winding section 50 Mounting base 51 5th cylinder 52 Fourth drive mechanism 53 Insertion groove 54 Sliding base 55 Winding Assembly 56 Rotation axis 57 Bush 58 Insert Sheet 59 Umbrella-shaped member 6 Jack-up section 60 Sliding rail 61 Sliding plate 62 Horizontal board 63 Positioning rod 64 racks 65 Third motor 66 First Gear 67 6th cylinder 7 Positioning part 70 Fixed plate 71 7th cylinder 72 No. 8 cylinder 73 Movable Block 74 Alignment Block 8-wire clamp assembly 80 pedestal 81 10th cylinder 82 No. 11 cylinder 83 First swing arm 84 Second swing arm 85 Drive gear 86 Driven gear 87 Belt 9 Locking Assembly 90 9th cylinder 91 steel ball 92 Rotary joint 93 Sliding sleeve 101 U-shaped hairpin copper wire 102 I-shaped copper wire

Claims

1. An automatic wire insertion process for a rectangular wire stator, Step S1: arranging copper wires in a plurality of wire arranging tools (2) in order based on the number of layers and the number of grooves of different stator winding structures; Step S2: sequentially sending the plurality of wire arranging tools (2) on which the copper wires are arranged to a wire winding mechanism; Step S3: a wire winding mechanism winds the copper wires arranged on the wire arranging tool (2) onto the winding assembly in order to form a predetermined winding structure; Step S4: transferring and inserting the predetermined winding structure into the stator; Including, When the stator winding has 6 layers and 48 grooves, the copper wire arrangement is as follows: S1: Three A copper wires and three B copper wires are alternately arranged from right to left on a single-turn wire arrangement tool (2), and the spacers between two straight sections of the A copper wires are six core grooves, among which the spacers between two straight sections of the B copper wires are four core grooves; S2: 36 C copper wires are stacked on the one-turn wire arrangement tool (2) in the arrangement order from left to right, and the wire arrangement of the one-turn wire arrangement tool (2) is completed; S3: 12 D copper wires are stacked on top of each other in order from right to left on the wire arrangement tool (2) wound twice, and after completing the arrangement of the D copper wires, 36 E copper wires are stacked on top of each other in order from left to right on the wire arrangement tool (2) wound twice, and the wire arrangement of the wire arrangement tool (2) wound twice is completed; S4: According to the arrangement method of the D copper wire and the E copper wire, the F copper wire and the G copper wire are arranged on the wire arrangement tool (2) wound three times, and the number of the G copper wires is the same as the number of the C copper wires; S5: Arrange the 12 H copper wires one by one on the wire arrangement tool (2) with three windings, and complete the wire arrangement on the wire arrangement tool (2) with three windings. This is an automatic wire insertion process for rectangular wire stator.

2. The automatic wire insertion process for a rectangular wire stator according to claim 1, characterized in that the A copper wire, the B copper wire, the C copper wire, the D copper wire, the E copper wire, the F copper wire and the G copper wire are all U-shaped hairpin copper wires (101), and the H copper wire is an I-shaped copper wire (102).

3. 3. The automatic wire insertion process for a rectangular wire stator according to claim 2, characterized in that, when the stator winding has six layers and 48 grooves, when the wire winding mechanism winds one turn, the A copper wire is wound from the first groove of the first layer of the stator and stops in the twelfth groove of the first layer, and the B copper wire is wound from the second groove of the first layer of the stator and stops in the eleventh groove of the first layer, and the A copper wire and the B copper wire do not overlap.

4. The automatic wire insertion process for a rectangular wire stator according to claim 3, characterized in that the C copper wire is wound from the 13th groove of the first layer of the stator, the C copper wires located in the 19th groove to the 48th groove are overlapped, and the overlapped C copper wires are respectively located in the first layer and the second layer of the stator, and the C copper wires located in the 1st groove to the 6th groove are installed in the second layer of the stator.

5. When the winding mechanism winds twice, the D copper wire is wound from the first slot of the third layer of the stator, the D copper wires located in the seventh slot to the twelfth slot are overlapped, and the overlapped D copper wires are located on the second and third layers of the stator, and the D copper wires located in the thirteenth slot to the eighteenth slot are installed on the second layer of the stator. The automatic wire insertion process for a rectangular wire stator according to claim 4.

6. The E copper wire is wound from the 13th groove of the 3rd layer, and the E copper wires located in the 19th groove to the 48th groove are overlapped, and the overlapped E copper wires are respectively located in the 3rd and 4th layers of the stator, and the E copper wires located in the 1st groove to the 6th groove are installed in the 4th layer of the stator. The automatic wire insertion process for a rectangular wire stator according to claim 4.

7. The G copper wire is wound from the 13th groove of the 5th layer and stopped in the 6th groove of the 6th layer; the G copper wires located in the 19th groove to the 48th groove are overlapped, and the overlapped G copper wires are respectively located in the 5th and 6th layers of the stator; the G copper wires located in the 1st groove to the 6th groove are installed in the 6th layer of the stator; and the H copper wire is wound from the 7th groove of the 6th layer and stopped in the 18th groove of the 6th layer. The automatic wire insertion process for a rectangular wire stator according to claim 6.

8. The wire winding mechanism includes a wire arranging tool (2) for arranging flat copper wires, a winding mechanism for winding the arranged flat copper wires, a flat copper wire transport mechanism, and a tool transport mechanism, which are installed in the stator winding device; The tool transport mechanism is used to transport the line arranging tool (2) to the winding mechanism, The flat copper wire conveying mechanism is used to convey the flat copper wires arranged on the wire arranging tool (2) conveyed to the winding mechanism and wind them. The automatic wire insertion process for a rectangular wire stator according to claim 1.

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