CN113452220B - Forming method of motor hairpin conductor - Google Patents
Forming method of motor hairpin conductor Download PDFInfo
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- CN113452220B CN113452220B CN202110754967.9A CN202110754967A CN113452220B CN 113452220 B CN113452220 B CN 113452220B CN 202110754967 A CN202110754967 A CN 202110754967A CN 113452220 B CN113452220 B CN 113452220B
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- 239000004020 conductor Substances 0.000 title claims abstract description 58
- 238000000034 method Methods 0.000 title claims abstract description 24
- 238000005452 bending Methods 0.000 claims abstract description 96
- 230000007246 mechanism Effects 0.000 claims description 76
- 238000000465 moulding Methods 0.000 claims description 59
- 230000000149 penetrating effect Effects 0.000 claims description 7
- 230000004888 barrier function Effects 0.000 claims description 6
- 238000003860 storage Methods 0.000 claims description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 abstract description 7
- 239000003973 paint Substances 0.000 abstract description 4
- 241001391944 Commicarpus scandens Species 0.000 abstract description 2
- 230000008569 process Effects 0.000 description 6
- 238000004804 winding Methods 0.000 description 6
- 230000000694 effects Effects 0.000 description 5
- 230000009471 action Effects 0.000 description 3
- 230000015556 catabolic process Effects 0.000 description 3
- 230000006872 improvement Effects 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000005674 electromagnetic induction Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 238000005457 optimization Methods 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
- H02K15/0414—Windings consisting of separate elements, e.g. bars, hairpins, segments, half coils
- H02K15/0421—Windings consisting of separate elements, e.g. bars, hairpins, segments, half coils consisting of single conductors, e.g. hairpins
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/64—Electric machine technologies in electromobility
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- Manufacturing & Machinery (AREA)
- Power Engineering (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
The invention discloses a method for forming a hairpin conductor of a motor, which is characterized by comprising the steps of firstly obtaining a forming die with the following structure, wherein the forming die comprises a first die body and a second die body which are oppositely arranged in use, one opposite sides of the first die body and the second die body are respectively a first forming surface and a second forming surface which are bent in a wave shape, and the first forming surface and the second forming surface are formed by extending a bent bus along a guide straight line, so that the first die body and the second die body can relatively move along the direction of the guide straight line when the first forming surface and the second forming surface are in a state of being close to each other; the method for forming the hair clip conductors of the motor has the advantages that the forming efficiency is high, the speed is high, a plurality of hair clip conductors can be formed simultaneously, the copper wire can be prevented from being stretched by bending and then bending, the paint coat cannot be stretched and thinned, the paint coat is not easy to break down, the reliability of the motor is improved, and the like.
Description
Technical Field
The invention relates to the technical field of motor production, in particular to a method for forming a hairpin conductor of a motor.
Background
The motor (including the motor and the generator) is a device for converting electric energy into mechanical energy (or converting mechanical energy into electric energy) according to the principle of electromagnetic induction, and can be used as a power source or a power generation device of various electric appliances such as household appliances, various machines such as electric vehicles and electric automobiles. The motors can be classified into dc motors and ac motors according to the kinds of their operating power sources, and the ac motors can be classified into single-phase motors and multi-phase motors (e.g., three-phase motors). The motor comprises a stator and a rotor, and a winding is arranged in a stator core slot of the stator. The traditional winding is formed by winding a round conducting wire, although the winding process is relatively simple, the space utilization rate in an iron core groove is low, useless copper at the end is greatly wasted, and the power density is low, so that the winding is gradually replaced by a flat copper wire or a copper wire with a rectangular cross section.
At present, a winding of a flat copper wire or a rectangular-section copper wire is mainly formed by welding hairpin conductors which are integrally bent in a U shape in a sectional manner, and during assembly, the hairpin conductors bent in the U shape are sequentially inserted into a stator core slot, and then one end of the hairpin conductors penetrating through the stator core slot is integrally bent in place layer by layer in the circumferential direction and then welded. The overall shape of the hairpin conductor is as shown in fig. 1 to 3, and as can be seen from fig. 1 and 2, the hairpin conductor is bent in a U-shape as a whole, and as can be seen from fig. 3, the hairpin conductor has a wave-shaped bend in the width direction.
Chinese patent document discloses a new energy motor coil forming stamping mechanism, a lower die and a baffle plate before forming are used for extruding a lead into a plane U-shaped bent shape, then an upper die is used for applying pressure to the plane U-shaped bent lead, and a curved surface at the edge of a stamping head of the lower die is used for forming the plane U-shaped bent lead.
Disclosure of Invention
Aiming at the defects of the prior art, the technical problems to be solved by the invention are as follows: how to provide a forming method of a motor hairpin conductor, which has good forming effect and small damage to a lead, can reduce the breakdown hidden danger and is beneficial to improving the reliability of a motor.
In order to solve the technical problem, the invention adopts the following technical scheme:
the forming method of the motor hairpin conductor is characterized in that a forming die with the following structure is obtained firstly, the forming die comprises a first die body and a second die body which are oppositely arranged in use, one opposite sides of the first die body and the second die body are respectively a first forming surface and a second forming surface which are bent in a wave shape, the first forming surface and the second forming surface are formed by extending bending buses along a guide straight line, and the first die body and the second die body can relatively move along the direction of the guide straight line in a state that the first forming surface and the second forming surface are close to each other;
the first forming surface and the second forming surface are respectively provided with a bending forming area and a bending forming area in the direction of the guide straight line, and in the direction of the guide straight line, the positions of the bending forming area and the bending forming area on the first forming surface are opposite to the positions of the bending forming area and the bending forming area on the second forming surface;
the bending forming area of the first forming surface is provided with a first forming boss which is formed in a protruding mode, a forming groove which penetrates through towards the bending forming area along a guide linear direction is formed in the middle of the first forming boss, the shape of the side wall of the forming groove is consistent with the outline shape of the hairpin conductor to be formed, and the forming groove is bent towards the side wall of the bending forming area to form an arc-shaped guide portion; the top of the first molding boss is provided with a third molding surface matched with the shape of the second molding surface; the height of the first forming boss is matched with the thickness of the hairpin conductor to be formed;
a second forming boss which is arranged corresponding to the forming groove is formed in the bending forming area of the second forming surface in a protruding mode, the height of the second forming boss is matched with the depth of the forming groove, and a fourth forming surface which is matched with the first forming surface in shape is arranged at the top of the second forming boss; the bending forming end of the second forming boss is arranged towards the bending forming area along the direction of the guide straight line, and the shape of the outer wall of the second forming boss is consistent with the shape of the inner contour of the hairpin conductor to be formed, so that the clearance between the second forming boss and the forming groove in a matching state is consistent with the forming shape of the hairpin conductor;
during forming, the first die body and the second die body are vertically arranged oppositely, the bending forming area of the first die body is vertically opposite to the bending forming area of the second die body, a flat wire to be formed is placed between the bending forming areas of the first die body and the second die body along the width direction, the first die body and the second die body are firstly pressed, the first die body and the second die body are relatively moved along the guide straight line direction, the second forming boss is extruded into the forming groove, and forming of the hairpin conductor is completed.
In the above structure, the first mold body and the second mold body may relatively move along the guiding straight line direction in a state where the first molding surface and the second molding surface are proximate to each other (i.e., mold press fit), that is, the first mold body and the second mold body may be press fit first and then relatively move along the guiding straight line direction. The bending forming areas on the first forming surface and the second forming surface are opposite to the bending forming areas in the direction of the guide straight line, so that the bending forming areas of the first forming surface and the second forming surface are oppositely arranged, a straight flat wire of the hairpin conductor to be formed is placed between the first forming surface and the second forming surface along the direction perpendicular to the guide straight line, the first die body and the second die body are pressed, and the straight flat wire forms wavy bending under the action of the first forming surface and the second forming surface; and then relatively moving the first die body and the second die body along the direction of the guide straight line, pushing the bent straight flat wire into the forming groove by using the second forming boss, and gradually bending and forming the straight flat wire under the pre-bending guide effect of the arc-shaped guide parts at two sides of the forming groove until the second forming boss completely slides into the forming groove, thereby completing the forming of the hairpin conductor. By adopting the forming die, the bending of the width direction of the hairpin conductor is finished firstly, and then the bending of the end part of the hairpin conductor is finished, so that the flat wire cannot be stretched in the length direction in the whole forming process, the reduction of the diameter of the flat wire and the stretching damage of the insulating layer are avoided, the risk of the breakdown of the insulating layer is reduced, and the reliability of the motor is improved.
Further, the first die body comprises a first main die body and a first auxiliary die body, a first mounting groove with the shape consistent with that of the side wall of the forming groove is formed in the middle of the first main body, the first mounting groove is arranged in a penetrating mode towards the direction of the bending forming area, and the first auxiliary die body is mounted in the first mounting groove; the third molding surface is located on the first master mold body, and the first molding surface is located on the first slave mold body;
the second die body comprises a second main die body and a second auxiliary die body, a second mounting groove with the shape consistent with that of the outer wall of the second forming boss is formed in the middle of the second main die body, the second mounting groove is arranged in a penetrating mode towards the direction of the bending forming area, and the second auxiliary die body is mounted in the second mounting groove; the fourth molding surface is located on the second sub mold body, and the second molding surface is located on the second main mold body.
Because the first molding surface, the second molding surface, the third molding surface and the fourth molding surface are all curved surfaces, the first molding surface and the third molding surface, and the second molding surface and the fourth molding surface are respectively arranged on different die bodies, so that the curved surfaces can be conveniently machined.
As optimization, a forming mechanism with the following structure is also obtained, wherein the forming mechanism comprises a first horizontal plate and a first vertical plate which are horizontally arranged;
a first linear guide mechanism is arranged on the first transverse plate, a first die holder is movably arranged on the first linear guide mechanism, and a first linear driving mechanism for driving the first die holder to horizontally move along the first linear guide mechanism is arranged between the first transverse plate and the first die holder;
the first vertical plate is provided with a vertically installed second linear guide mechanism, a second die holder is movably installed on the second linear guide mechanism, and a second linear driving mechanism used for driving the second die holder to vertically move along the second linear guide mechanism is further arranged between the first vertical plate and the second die holder;
the first die body and the second die body are arranged oppositely in the vertical direction, one of the first die body and the second die body is installed on the first die holder, and the other one of the first die body and the second die body is installed on the second die holder; the guide direction of the first linear guide mechanism is consistent with the guide linear directions of the first die body and the second die body; the bending forming area of the first die body is vertically opposite to the bending forming area of the second die body.
In the structure, the bending forming area of the first die body is vertically opposite to the bending forming area of the second die body, the straight flat wire is placed between the first die body and the second die body along the width direction, the second linear driving mechanism is started to drive the second die holder to vertically move, the first die body and the second die body are pressed, the straight flat wire is bent by the first forming surface and the second forming surface, then the first linear driving mechanism is started to drive the first die holder to horizontally move, the bent straight flat wire is pushed and extruded into the forming groove by the second forming boss, the straight flat wire is under the pre-bending guiding effect of the arc guiding parts on two sides of the forming groove, the straight flat wire is gradually bent and formed until the second forming boss completely slides into the forming groove, and therefore the forming of the hairpin conductor is completed.
Further, the second die holder is located under the first die holder, and both sides in the moving direction of the second die holder are provided with brackets for horizontally placing to-be-formed flat wires, the projection of the article placing part of the bracket on the vertical direction is located in the bending forming area of the first die body and the second die body, the height of the article placing part is located between the first die body and the second die body, and a space for the to-be-formed flat wires to move along with the first linear driving mechanism and the second linear driving mechanism is arranged above the bracket.
Due to the fact that the first forming surface and the second forming surface of the bending forming area are both wavy, the flat wire (straight flat wire) to be formed is not easy to horizontally and stably place between the first die body and the second die body, the flat wire to be formed is placed on the placing portion of the bracket by adopting the structure, the flat wire to be formed is horizontally and stably placed between the first die body and the second die body, the second linear driving mechanism drives the second die holder to move upwards, meanwhile, the flat wire to be formed is pushed to move upwards, bending of the flat wire to be formed is completed when the first die body and the second die body are pressed, and then bending is completed under the effect of the first linear driving mechanism.
Furthermore, the bracket is a vertical plate vertically installed on the first transverse plate, and the lower end of the vertical plate protrudes along the bending forming direction of the first linear driving mechanism to form the object placing part.
The bending forming direction of the first linear driving mechanism is the action direction of the first linear driving mechanism driving the first die holder to move to complete bending forming.
Furthermore, a barrier strip which is vertically arranged is arranged at the end part of the object placing part, a guide groove is formed between the barrier strip and the vertical plate, and the width of the guide groove is matched with the width of the flat wire to be formed; the upper end of the blocking strip is lower than the lowest height of the first die body or the second die body arranged on the first die holder.
Therefore, the flat wire to be formed is always guided by the guide groove in the process of moving upwards along with the second linear driving mechanism, so that the flat wire to be formed is prevented from swinging in the horizontal direction.
Furthermore, one side of the first transverse plate or the first vertical plate is also provided with a limit baffle plate which is vertically arranged, so that one end of the to-be-molded flat wire which is placed on the bracket placing part can be abutted against the limit baffle plate.
Therefore, the uniform placement positions of the flat wires to be molded can be guaranteed through the limiting baffle, so that the bending and bending positions can be controlled, and the consistency of the molded hairpin conductor is better.
Furthermore, two sides of the first linear guide mechanism are respectively provided with a limiting block, and the limiting blocks are opposite to the first die holder in the guide direction of the first linear guide mechanism.
Furthermore, the limiting block is provided with a threaded hole which faces the first die holder and is arranged in a penetrating mode, the threaded hole is provided with a limiting stud, and the limiting stud is further provided with a locking nut.
Further, the first linear guide mechanism and the second linear guide mechanism are both linear guide rails; the first linear driving mechanism and the second linear driving mechanism are both cylinders; the other end of the first transverse plate is also provided with a second vertical plate which is arranged in parallel with the first vertical plate, and the lower ends of the first vertical plate and the second vertical plate are provided with a second transverse plate; the first linear driving mechanism is installed on the second vertical plate, and the second linear driving mechanism is installed on the second transverse plate.
In conclusion, the method for forming the hair clip conductors of the motor has the advantages that the forming efficiency is high, the speed is high, a plurality of hair clip conductors can be formed simultaneously, the copper wire can be prevented from being stretched by bending and then bending, the paint coat cannot be stretched and thinned, the paint coat is not easy to break down, the reliability of the motor is improved, and the like.
Drawings
Fig. 1 to 3 are schematic structural diagrams of hairpin conductors.
Fig. 4 is an exploded view of the forming die.
Fig. 5 is a schematic structural view of the second mold body.
Fig. 6 to 8 are schematic structural views of the molding mechanism.
Detailed Description
The present invention will be described in further detail with reference to examples.
In the specific implementation: as shown in fig. 6 to 8, a forming mechanism for a motor hairpin conductor includes a first horizontal plate 3 horizontally disposed and a first vertical plate 4 vertically disposed, a second vertical plate 8 parallel to the first vertical plate 4 is further provided at the other end of the first horizontal plate 3, and a second horizontal plate 9 is installed at the lower ends of the first vertical plate 4 and the second vertical plate 8.
The first transverse plate 3 is provided with a first linear guide mechanism 31, the first linear guide mechanism 31 is movably provided with a first die holder 32, a first linear driving mechanism 33 used for driving the first die holder 32 to horizontally move along the first linear guide mechanism 31 is further arranged between the first transverse plate 3 and the first die holder 32, and the first linear driving mechanism 33 is arranged on the second vertical plate 4. The first vertical plate 4 is provided with a second linear guide mechanism 41 which is vertically installed, the second linear guide mechanism 41 is movably installed with a second die holder 42, a second linear driving mechanism 43 which is used for driving the second die holder 42 to vertically move along the second linear guide mechanism 41 is further arranged between the first vertical plate 4 and the second die holder 42, and the second linear driving mechanism 43 is installed on the second transverse plate 9.
In this embodiment, the first linear guide mechanism 31 and the second linear guide mechanism 41 are both linear guide rails, and are both provided with two linear guide rails, and the first die holder 32 and the second die holder 42 are installed on the linear guide rails through sliders. The first linear driving mechanism 33 and the second linear driving mechanism 43 are both air cylinders.
The first die holder 32 and the second die holder 42 are further provided with forming dies for motor hairpin conductors, as shown in fig. 4 and 5, the forming dies comprise a first die body 1 and a second die body 2 which are vertically arranged in an opposite manner, one of the forming dies is arranged on the first die holder 32, and the other forming die is arranged on the second die holder 42; the opposite sides of the first die body 1 and the second die body 2 are respectively provided with a first forming surface 11 and a second forming surface 21 which are bent in a wave shape, the first forming surface 11 and the second forming surface 21 are formed by extending bending generatrices along a guide straight line, so that the first die body 1 and the second die body 2 can relatively move along the direction of the guide straight line under the state that the first forming surface 11 and the second forming surface 21 are close to each other;
the first molding surface 11 and the second molding surface 21 are respectively provided with a bending molding area B and a bending molding area A in the direction of the guide straight line, and in the direction of the guide straight line, the directions of the bending molding area B and the bending molding area A on the first molding surface 11 are opposite to the directions of the bending molding area B and the bending molding area A on the second molding surface 21;
the bending forming area A of the first forming surface 11 is provided with a first forming boss 12 which is formed in a protruding mode, a forming groove 13 which penetrates through towards the bending forming area B along the direction of a guide straight line is formed in the middle of the first forming boss 12, the shape of the side wall of the forming groove 13 is consistent with the shape of the outline of the hairpin conductor to be formed, and the side wall of the forming groove 13, which faces towards the bending forming area B, is bent outwards to form an arc-shaped guide portion 15; the top of the first forming boss 12 has a third forming surface 14 matching the shape of the second forming surface 21; the height of the first forming boss 12 is matched with the thickness of the hairpin conductor to be formed. In specific implementation, the thickness of the hairpin conductor to be formed is an integral multiple of the thickness of a single hairpin conductor, for example, the height of the first forming boss 12 is matched with the sum of the thicknesses of the 5 hairpin conductors, so that the 5 hairpin conductors can be formed at one time after being stacked, that is, the 5 stacked hairpin conductors are 1 hairpin conductor to be formed.
A second forming boss 22 corresponding to the forming groove 13 is formed in the bending forming area a of the second forming surface 21 in a protruding manner, the height of the second forming boss 22 is matched with the depth of the forming groove 13, and a fourth forming surface 23 matched with the shape of the first forming surface 11 is arranged at the top of the second forming boss 22; the bending forming end of the second forming boss 22 is arranged towards the bending forming area B along the direction of the guide straight line, and the shape of the outer wall of the second forming boss 22 is consistent with the shape of the inner contour of the hairpin conductor to be formed, so that the clearance between the second forming boss 22 and the forming groove 13 in the matching state is consistent with the forming shape of the hairpin conductor.
The bending forming area B of the first die body 1 is vertically opposite to the bending forming area B of the second die body 2, and the guide direction of the first linear guide mechanism 31 is consistent with the guide linear direction of the first die body 1 and the guide linear direction of the second die body 2.
The first die body and the second die body can relatively move along the direction of the guide straight line when the first molding surface and the second molding surface are close to each other (namely, the die is pressed), namely, the first die body and the second die body can be pressed firstly and then relatively move along the direction of the guide straight line. The bending forming area B and the bending forming area A on the first forming surface and the second forming surface are opposite in direction of the guide straight line, so that the bending forming area B of the first forming surface and the second forming surface are oppositely arranged, the straight flat wire of the hairpin conductor to be formed is placed between the first forming surface and the second forming surface along the direction perpendicular to the guide straight line, the second straight line driving mechanism is started to drive the second die holder to move vertically, the first die body and the second die body are pressed together, the straight flat wire is bent by using the first forming surface and the second forming surface, then the first straight line driving mechanism is started to drive the first die holder to move horizontally, the second forming boss pushes the bent straight flat wire into the forming groove, the straight flat wire is bent and formed gradually under the pre-bending guide effect of the arc-shaped guide parts on two sides of the forming groove until the second forming boss completely slides into the forming groove, thereby completing hairpin conductor formation. In the forming process, the bending of the width direction of the hairpin conductor is finished firstly, and then the bending of the end part of the hairpin conductor is finished, so that the flat wire cannot be stretched in the length direction in the whole forming process, the reduction of the diameter of the flat wire and the stretching damage of the insulating layer are avoided, the risk of the breakdown of the insulating layer is reduced, and the improvement of the reliability of the motor is facilitated.
During implementation, the second die holder 42 is located under the first die holder 32, and the two sides in the moving direction are provided with the bracket 5 for horizontally placing the flat wire to be formed, the projection of the object placing part of the bracket 5 in the vertical direction is located in the bending forming area B of the first die body 1 and the second die body 2, the height of the object placing part is located between the first die body 1 and the second die body 2, and a space for the flat wire to be formed to move along with the first linear driving mechanism and the second linear driving mechanism is arranged above the bracket 5.
Due to the fact that the first forming surface and the second forming surface of the bending forming area B are wavy, the flat wire (straight flat wire) to be formed is not easy to place horizontally and stably between the first forming surface and the second forming surface.
In practice, the bracket 5 is a vertical plate 51 vertically mounted on the first horizontal plate 3, and the lower end of the vertical plate 51 protrudes in the bending direction of the first linear driving mechanism to form the storage portion 52.
The bending forming direction of the first linear driving mechanism is the action direction of the first linear driving mechanism driving the first die holder to move to complete bending forming.
When the forming machine is used, the end part of the object placing part 51 is provided with a barrier strip 53 which is vertically arranged, a guide groove is formed between the barrier strip 53 and the vertical plate 51, and the width of the guide groove is matched with the width of a flat wire to be formed; the upper end of the barrier 53 is lower than the lowest height of the first mold body or the second mold body mounted on the first mold base 32.
Therefore, the flat wire to be formed is always guided by the guide groove in the process of moving upwards along with the second linear driving mechanism, so that the flat wire to be formed is prevented from swinging in the horizontal direction.
When the forming device is used, one side of the first transverse plate 3 or the first vertical plate 4 is also provided with a limit baffle 6 which is vertically arranged, so that one end of a flat wire to be formed which is placed on the placing part of the bracket 5 can be abutted against the limit baffle 6.
Therefore, the uniform placement positions of the flat wires to be molded can be guaranteed through the limiting baffle, so that the bending and bending positions can be controlled, and the consistency of the molded hairpin conductor is better.
During implementation, two sides of the first linear guide mechanism 31 are respectively provided with a limiting block 7, and the limiting blocks 7 are opposite to the first die holder 32 in the guide direction of the first linear guide mechanism 31.
During implementation, the limiting block 7 is provided with a threaded hole which is formed by penetrating the first die holder 32, the threaded hole is provided with a limiting stud, and the limiting stud is further provided with a locking nut.
In implementation, the first die body 1 includes a first main die body 16 and a first sub die body 17, a first mounting groove having a shape identical to that of a side wall of the forming groove 13 is formed in the middle of the first main body 16, the first mounting groove is arranged to penetrate in a direction of a bending forming area B, and the first sub die body 17 is mounted in the first mounting groove; said third molding surface 14 is located on said first master mold 16 and said first molding surface 11 is located on said first slave mold 17;
the second mold body 2 comprises a second main mold body 24 and a second auxiliary mold body 25, a second mounting groove with the same shape as the outer wall of the second forming boss 22 is formed in the middle of the second main mold body 24, the second mounting groove is arranged in a penetrating manner in the direction of the bending forming area B, and the second auxiliary mold body 25 is mounted in the second mounting groove; the fourth molding surface 23 is located on the second sub-mold 25, and the second molding surface 21 is located on the second main mold 24.
Because the first molding surface, the second molding surface, the third molding surface and the fourth molding surface are all curved surfaces, the first molding surface and the third molding surface, and the second molding surface and the fourth molding surface are respectively arranged on different die bodies, so that the curved surfaces can be conveniently machined.
The above description is only exemplary of the present invention and should not be taken as limiting, and any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. The forming method of the motor hairpin conductor is characterized by comprising the steps of firstly obtaining a forming die with the following structure, wherein the forming die comprises a first die body (1) and a second die body (2) which are oppositely arranged in use, one sides, opposite to the first die body (1) and the second die body (2), of the first forming surface (11) and the second forming surface (21) which are bent in a wave shape respectively, the first forming surface (11) and the second forming surface (21) are formed by extending bending buses along a guide straight line, and the first die body (1) and the second die body (2) can relatively move along the direction of the guide straight line when the first forming surface (11) and the second forming surface (21) are in a state of being close to each other;
the first molding surface (11) and the second molding surface (21) are provided with a bending molding area and a bending molding area in the direction of the guide straight line, and the directions of the bending molding area and the bending molding area on the first molding surface (11) are opposite to the directions of the bending molding area and the bending molding area on the second molding surface (21) in the direction of the guide straight line;
the bending forming area of the first forming surface (11) is provided with a first forming boss (12) which is formed in a protruding mode, a forming groove (13) which penetrates through towards the bending forming area along a guide linear direction is formed in the middle of the first forming boss (12), the shape of the side wall of the forming groove (13) is consistent with the shape of the outline of the hairpin conductor to be formed, and the forming groove (13) is bent outwards towards the side wall of the bending forming area to form an arc-shaped guide portion (15); the top of the first forming boss (12) is provided with a third forming surface (14) matched with the shape of the second forming surface (21); the height of the first forming boss (12) is matched with the thickness of the hairpin conductor to be formed;
a second forming boss (22) which is arranged corresponding to the forming groove (13) is formed in the bending forming area of the second forming surface (21) in a protruding mode, the height of the second forming boss (22) is matched with the depth of the forming groove (13), and a fourth forming surface (23) which is matched with the shape of the first forming surface (11) is arranged at the top of the second forming boss (22); the bending forming end of the second forming boss (22) is arranged towards the bending forming area along the direction of a guide straight line, and the shape of the outer wall of the second forming boss (22) is consistent with the shape of the inner contour of the hairpin conductor to be formed, so that the clearance between the second forming boss (22) and the forming groove (13) in a matching state is consistent with the forming shape of the hairpin conductor;
during forming, the first die body and the second die body are vertically arranged oppositely, the bending forming area of the first die body is vertically opposite to the bending forming area of the second die body, a flat wire to be formed is placed between the bending forming areas of the first die body and the second die body along the width direction, the first die body and the second die body are firstly pressed, then the first die body and the second die body are relatively moved along the guide straight line direction, the second forming boss is extruded into the forming groove, and forming of the hairpin conductor is completed.
2. The method for molding a motor hairpin conductor according to claim 1, wherein the first mold body (1) includes a first main mold body (16) and a first sub-mold body (17), a middle portion of the first main mold body (16) having a first fitting groove conforming in shape to a side wall of the molding recess (13), the first fitting groove being disposed to penetrate toward a press bending molding region, the first sub-mold body (17) being fitted in the first fitting groove; -said third molding surface (14) is located on said first master-mould body (16), said first molding surface (11) is located on said first slave-mould body (17);
the second die body (2) comprises a second main die body (24) and a second auxiliary die body (25), a second mounting groove which is consistent with the outer wall of the second forming boss (22) in shape is formed in the middle of the second main die body (24), the second mounting groove is arranged in a penetrating mode towards the direction of a bending forming area, and the second auxiliary die body (25) is mounted in the second mounting groove; the fourth molding surface (23) is located on the second sub-mold body (25), and the second molding surface (21) is located on the second main mold body (24).
3. The method for forming the hairpin conductor of the motor according to claim 1, further obtaining a forming mechanism having a structure including a first horizontal plate (3) horizontally disposed and a first vertical plate (4) vertically disposed;
a first linear guide mechanism (31) is installed on the first transverse plate (3), a first die holder (32) is movably installed on the first linear guide mechanism (31), and a first linear driving mechanism (33) used for driving the first die holder (32) to horizontally move along the first linear guide mechanism (31) is further arranged between the first transverse plate (3) and the first die holder (32);
a second linear guide mechanism (41) which is vertically installed is arranged on the first vertical plate (4), a second die holder (42) is movably installed on the second linear guide mechanism (41), and a second linear driving mechanism (43) which is used for driving the second die holder (42) to vertically move along the second linear guide mechanism (41) is further arranged between the first vertical plate (4) and the second die holder (42);
the first die body (1) and the second die body (2) are arranged oppositely in the vertical direction, one of the first die body and the second die body is arranged on the first die holder (32), and the other one of the first die body and the second die body is arranged on the second die holder (42); the guiding direction of the first linear guiding mechanism (31) is consistent with the guiding linear direction of the first die body (1) and the second die body (2); the bending forming area of the first die body (1) is vertically opposite to the bending forming area of the second die body (2).
4. The method for forming the motor hairpin conductor according to claim 3, wherein the second die holder (42) is located directly below the first die holder (32), and brackets (5) for horizontally placing the flat wire to be formed are provided on both sides in the moving direction of the first die holder and the second die holder, the projection of the placement part of the brackets (5) in the vertical direction is located in the bending forming area of the first die body (1) and the second die body (2), the height of the placement part is located between the first die body (1) and the second die body (2), and a space for the flat wire to be formed to move along with the first linear driving mechanism and the second linear driving mechanism is provided above the brackets (5).
5. The method for forming the hairpin conductor according to claim 4, wherein the bracket (5) is a vertical plate (51) vertically mounted on the first horizontal plate (3), and the lower end of the vertical plate (51) protrudes in the bending forming direction of the first linear drive mechanism to form the storage part (52).
6. The method for forming the motor hairpin conductor according to claim 5 wherein the end of the placement part (52) has a vertically disposed bar (53), a guide groove is formed between the bar (53) and the vertical plate (51), and the width of the guide groove matches with the width of the flat wire to be formed; the upper end of the barrier strip (53) is lower than the lowest height of the first die body or the second die body arranged on the first die holder (32).
7. The method for forming the hairpin conductor of the motor according to claim 4, wherein one side of the first horizontal plate (3) or the first vertical plate (4) is further provided with a vertically arranged limit baffle (6), so that one end of the flat wire to be formed placed on the placing part of the bracket (5) can be abutted against the limit baffle (6).
8. The method for forming the hair fastener of the motor according to claim 4, wherein two sides of the first linear guide mechanism (31) are respectively provided with a limiting block (7), and the limiting blocks (7) are opposite to the first mold holder (32) in the guiding direction of the first linear guide mechanism (31).
9. The method for forming the motor hairpin conductor of claim 8 wherein the stopper (7) has a threaded hole through toward the first die holder (32), the threaded hole being provided with a stopper stud, the stopper stud being further provided with a lock nut.
10. The method of claim 4, wherein said first linear guide (31) and said second linear guide (41) are linear guides; the first linear driving mechanism (33) and the second linear driving mechanism (43) are both cylinders; the other end of the first transverse plate (3) is also provided with a second vertical plate (8) which is arranged in parallel with the first vertical plate (4), and the lower ends of the first vertical plate (4) and the second vertical plate (8) are provided with a second transverse plate (9); the first linear driving mechanism (33) is installed on the second vertical plate (8), and the second linear driving mechanism (43) is installed on the second transverse plate (9).
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| CN114082871B (en) * | 2021-11-30 | 2023-08-22 | 深圳市金岷江智能装备有限公司 | Flat wire forming device and flat wire forming method |
| CN115664139B (en) * | 2022-11-17 | 2023-11-10 | 跃科智能制造(无锡)有限公司 | Multi-line flat copper wire forming equipment for hairpin motor stator |
| CN116032082B (en) * | 2023-03-28 | 2023-06-02 | 邦迪智能装备(河南)有限公司 | Coil forming equipment for flat wire motor stator production |
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| JPS6070951A (en) * | 1983-09-26 | 1985-04-22 | Hitachi Ltd | Flat wire u-shaped automatic bending machine |
| JP4600487B2 (en) * | 2008-02-13 | 2010-12-15 | 株式会社デンソー | Method for manufacturing circumferentially developed stator coil and motor using this circumferentially developed stator coil |
| US20160254718A1 (en) * | 2015-02-26 | 2016-09-01 | Nidec Copal Corporation | Segment conductors, stator, rotating electrical machine, and vehicle and method of manufacturing the segment conductors |
| CN109149882A (en) * | 2017-06-28 | 2019-01-04 | 天津市松正电动汽车技术股份有限公司 | A kind of motor flat type copper wire molding equipment and technique |
| CN109586448A (en) * | 2017-09-29 | 2019-04-05 | 比亚迪股份有限公司 | Conductor segment and stator module, motor with it |
| CN108988593B (en) * | 2018-08-09 | 2020-05-08 | 苏州阿福机器人有限公司 | Method for producing a winding for an electric machine and winding arrangement |
| US10965178B2 (en) * | 2018-11-28 | 2021-03-30 | Ford Global Technologies, Llc | Hairpin winding electric machine |
| CN110380547B (en) * | 2019-07-12 | 2021-02-26 | 合肥巨一动力系统有限公司 | Flat wire motor stator |
| CN110640050B (en) * | 2019-08-28 | 2020-06-23 | 安徽巨一自动化装备有限公司 | Flat copper wire bending forming device |
| CN111509925B (en) * | 2020-04-14 | 2023-02-03 | 安徽巨一科技股份有限公司 | Flat wire motor stator plane hairpin forming device |
| CN212012282U (en) * | 2020-05-28 | 2020-11-24 | 重庆宗申电动力科技有限公司 | Stator module and motor |
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Denomination of invention: A Forming Method for Motor Card Conductor Effective date of registration: 20231016 Granted publication date: 20220517 Pledgee: Chongqing Zongshen Jiyan Mechanical and Electrical Technology Co.,Ltd. Pledgor: CHONGQING ZONGSHEN ELECTRIC POWER TECHNOLOGY Co.,Ltd. Registration number: Y2023980061209 |