Forming apparatus of flat litz wire coil

Abstract

A forming apparatus for a flat Ritz coil includes a base unit, a forming unit, and a bending unit. The base unit includes a mounting platform. The forming unit includes a pressing mechanism mounted on the mounting platform and a twisting mechanism located on one side of the pressing mechanism in a front-rear direction. The bending unit includes a first bending mechanism, two first push blocks pivotally connected to the first bending mechanism, two second bending mechanisms, and two second push blocks respectively pivotally connected to the second bending mechanisms. The first bending mechanism and the second bending mechanisms can drive the first and second push blocks to push against a flat wire, causing the flat wire to be deformed into a 2D shape against the pressing mechanism. The twisting mechanism can further twist the flat wire to form a flat Ritz coil with 3D features.

Claims

1. A forming apparatus for a flat Ritz coil, defining a lateral direction perpendicular to each other, a front-back direction, and a lifting direction, the forming apparatus comprising: a base unit including a mounting platform and two lifting mechanisms disposed on the mounting platform, the mounting platform having a plurality of inner guide grooves spaced apart from each other along the lateral direction and a plurality of outer guide grooves spaced apart from each other along the lateral direction, each outer guide groove being located on one side of one of the inner guide grooves; A forming unit includes a pressing mechanism disposed on the setting platform and a twisting mechanism disposed opposite to the pressing mechanism in the front-back direction. The pressing mechanism has a block located laterally between the inner guide grooves and a pressing power source capable of driving the block to move in the front-back direction. A folding unit includes a first folding mechanism disposed on the setting platform, two first push blocks pivotally connected to the first folding mechanism and movable along the inner guide grooves by the first folding mechanism, two second folding mechanisms respectively movable along the lifting direction by the lifting mechanism, and two second push blocks respectively pivotally connected to the second folding mechanism and movable along the outer guide grooves by the second folding mechanism. Each first push block is recessed to form a first limiting groove, and each second push block is recessed to form a second limiting groove.

2. The forming apparatus for flat Ritz coils as described in claim 1, wherein, The mounting platform of the base unit also has two through slots that correspond to the second folding mechanisms and pass through the lifting direction, and a mounting slot located laterally between the first push blocks of the folding unit and passing through the lifting direction. The lifting mechanisms are located below the mounting platform. Each second folding mechanism can be driven by the corresponding lifting mechanism to pass through the corresponding through slot in the lifting direction. The twisting mechanism of the forming unit is at least partially located in the mounting slot.

3. The forming apparatus for flat Ritz coils as described in claim 2, wherein, The first folding mechanism of the folding unit has a folding cylinder located outside the mounting slot along the front-rear direction and fixed to the mounting platform of the base unit, and two connecting rods pivotally connected to the folding cylinder and respectively pivotally connected to the first push blocks. Each folding mechanism has a linear actuator pivotally connected to the corresponding second push block.

4. The flat Ritz coil forming apparatus as described in claim 1 further includes an auxiliary unit disposed on the base unit, the auxiliary unit including an auxiliary pressure cylinder fixed to the mounting platform of the base unit, and a positioning block connected to the auxiliary pressure cylinder and located laterally outside one of the first push blocks of the folding unit, the auxiliary pressure cylinder being capable of moving the positioning block, the positioning block having a positioning surface with a normal direction parallel to the lateral direction.

5. The forming apparatus for flat Ritz coils as described in claim 1, wherein, The base unit also includes a mounting base disposed on the mounting platform. The mounting base has a plurality of supports extending upward from the mounting platform along the lifting direction, and a seat plate connected to the supports and located above the pressing mechanism of the forming unit. The forming equipment also includes a molding unit, which includes a lower mold base disposed on the abutment block of the forming unit, a mold closing cylinder disposed on the seat plate, and an upper mold base connected to the mold closing cylinder and located above the lower mold base along the lifting direction. The mold closing cylinder can be controlled to drive the upper mold base to move toward the lower mold base along the lifting direction.

6. The forming apparatus for flat Ritz coils as described in claim 1, wherein, The inner guide channels of the mounting platform extend along the front-rear direction and approach each other, and the outer guide channels have a first section extending along the front-rear direction and approaching each other, and a second section extending along the side and approaching each other.

7. The forming apparatus for flat Ritz coils as described in claim 1, wherein, The forming unit has two first pressing surfaces that are interconnected and whose normal direction is perpendicular to the lifting direction, two second pressing surfaces that are respectively connected to the first pressing surfaces and whose normal direction is perpendicular to the lifting direction, and a limiting surface that is connected to and perpendicular to the first pressing surfaces and the second pressing surfaces.

8. The forming apparatus for flat Ritz coils as described in claim 2, wherein, The twisting mechanism of the forming unit has an actuating cylinder disposed below the setting platform along the lifting direction, a drive assembly that can be driven by the actuating cylinder to move along the front-back direction and has a portion extending through the setting groove along the lifting direction, and a torsion bar extending from the drive assembly toward the pressing mechanism along the front-back direction. The drive assembly can drive the torsion bar to rotate along a rotation axis parallel to the front-back direction, and the torsion bar has a groove facing the pressing block.

Images