Method of manufacturing yokeless axial flux core

Abstract

A method for manufacturing a yokeless axial flux core includes the following steps: feeding an electromagnet coil to the inlet of a stacking fixture via a feeding mechanism; cutting the electromagnet coil into a plurality of loose pieces via a stamping assembly, each of the loose pieces having a cutting length, and sequentially stamping the plurality of loose pieces downwards into the stacking fixture from the inlet to stack them, wherein the cutting length of each loose piece in the same stacking fixture is greater than the cutting length of the loose piece immediately stacked above it; finally, shaping the stacked loose pieces and combining them into a core by welding, impregnation, or self-adhesive coating activation.

Claims

1. A method for manufacturing a yokeless axial flux core, comprising the following steps: Step S10: feeding an electromagnet coil to a stacking fixture via a feeding mechanism; and Step S20: cutting the electromagnet coil into a plurality of loose pieces via a stamping assembly, each of the loose pieces being cut and then pressed downward into the stacking fixture via the stamping assembly to stack the plurality of loose pieces, wherein each loose piece has a cut length after being cut, and the cut length of each loose piece in the same stacking fixture is greater than the cut length of the loose piece immediately stacked thereon.

2. The method for manufacturing a yokeless axial flux core as described in claim 1, wherein the stacking fixture includes two correspondingly arranged movable sides and a bottom, one end of each of the two movable sides is pivotally connected to both ends of the bottom, and the two movable sides are movable and fixed in multiple positions relative to the bottom, and the stacking fixture has at least a pre-forming position, in which the two movable sides are perpendicular to the bottom and form a stacking space with the bottom, and the plurality of loose pieces are pressed into the stacking space and stacked.

3. The method for manufacturing a yokeless axial flux core as described in claim 2, wherein the stacking fixture includes a piece-bearing lifting member, including a lifting member and a carrying platform, one end of the lifting member being connected to the bottom of the stacking fixture, and the other end of the lifting member being connected to the carrying platform, the carrying platform being movable between the stamping assembly and the bottom through the lifting of the lifting member, and having multiple carrying heights from the bottom for carrying the corresponding piece stamped into the stacking fixture at a specific carrying height, wherein in the same stacking fixture, the carrying height corresponding to each piece is greater than the carrying height corresponding to the piece immediately stacked thereon.

4. The method for manufacturing a yokeless axial flux core as described in claim 1, wherein in step S20, the electromagnet coil is cut into the plurality of loose pieces by the stamping assembly under the continuous operation of the feeding mechanism, and the cutting length of the loose pieces is changed by changing the feeding speed of the feeding mechanism.

5. A method for manufacturing a yokeless axial flux core as claimed in claim 1, wherein there are a plurality of stacking fixtures and they are disposed on a conversion device, the conversion device defining a stamping position at a position corresponding to the stamping assembly, the conversion device being configured to convert one of the plurality of stacking fixtures to the stamping position, wherein step S20 is performed on the stacking fixture at the stamping position.

6. The method for manufacturing a yokeless axial flux core as described in claim 5, wherein the stamping assembly sequentially performs multiple stamping processes, each stamping process corresponding to a different shearing length of the electromagnet coil, the shearing length in each stamping process being greater than the shearing length in the immediately following stamping process, and each stamping process including at least one shearing and stamping operation performed by the stamping assembly in the conversion device to convert all the plurality of stacking fixtures to the stamping position.

7. A method for manufacturing a yokeless axial flux core as described in claim 5, wherein after the stacking fixture at the stamping position completes the stacking of all the loose pieces by performing step S20, another stacking fixture that has not yet performed step S20 is moved to the stamping position by the conversion of the conversion device to perform step S20.

8. A method for manufacturing a yokeless axial flux core as described in claim 5, wherein the conversion device is a turntable, and a plurality of the stacking fixtures are radially arranged at intervals on the turntable, the turntable moving a specific stacking fixture to the stamping position by rotation.

9. A method for manufacturing a yokeless axial flux core as described in claim 2, wherein the stamping assembly is disposed above the stacking fixture and includes a punch member and a die member, the die member being disposed parallel to the bottom on one of the movable sides and located outside the stacking space, and one side of the die member being aligned with the inner side of the one of the movable sides in the pre-forming position; the punch member being disposed perpendicular to the bottom on the die member, and the punch member being located within the stacking space when the two movable sides are in the pre-forming position.

10. A method for manufacturing a yokeless axial flux core as described in claim 9, wherein in step S20, while the electromagnet coil is cut into the plurality of loose pieces by the stamping assembly, a pressing member is used to fix the plurality of loose pieces, the pressing member is disposed above the die core member and forms a space with the die core member for the electromagnet coil to pass through, and the pressing member is located outside the stacking space, wherein when the stamping assembly cuts the electromagnet coil, the punch member is aligned with one side of the pressing member.

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