CN117862363A - Three-dimensional forming tool and process for hairpins for disc type motor - Google Patents

Abstract

The invention discloses a three-dimensional forming tool and a three-dimensional forming process of a hairpin line for a disc motor, wherein the three-dimensional forming tool comprises a workbench, a stamping mechanism arranged on the workbench, a quick-change assembly arranged at the stamping mechanism, and a first module, a second module and a third module which are matched with the quick-change assembly; the copper wire used in the more complicated winding mode can be subjected to efficient 3D forming operation, the whole work flow is concise, workers can conveniently operate, compared with traditional stamping equipment, the 3D copper wire forming is realized in a three-time stamping mode, multiple stamping equipment is not needed, three modules which are modularized and detachable are adopted to carry out different stamping operations, funds and space of a factory building are saved, the efficient stamping effect is achieved, the installation and the disassembly modes are simple and convenient, and the operation is easy.

Description

Three-dimensional forming tool and process for hairpins for disc type motor

Technical Field

The invention belongs to the technical field of flat wire forming, and particularly relates to a three-dimensional forming tool and a three-dimensional forming process of a hairclip wire for a disc motor.

Background

With the development of high performance, high efficiency and high power density of automobile driving motors, flat wire motors are gradually popular targets of new energy automobile driving motors at present due to high slot filling rate, high heat dissipation efficiency and good NVH (noise, vibration and harshness) characteristics.

The windings are the main components of the motor, and the motor generates electromagnetic power and electromagnetic torque by inducing electric potential in the windings and current passing through the windings, so that the purpose of energy conversion is achieved. The winding structure parameters such as the winding turns conductor section, the space distribution, the connection mode, the insulation level and the like are different, and the electromagnetic performance and the capability indexes are different.

The flat wire winding is a common motor winding type, and is characterized in that the cross section of the coil is flat rectangular instead of circular, and the winding type has wide application in motor design and can improve the efficiency and performance of the motor.

The flat wire winding has the advantages that the filling factor of the coil can be improved, and the coil can be more tightly arranged on the iron core of the motor due to the flat rectangular cross section, so that the filling factor of the coil is improved, the magnetic leakage of the motor can be reduced, and the efficiency and the power density of the motor are improved; meanwhile, the loss of the motor can be reduced, and the coil cross section area of the flat wire winding is larger than that of the round coil, so that the resistance and current density of the coil can be reduced, and the copper loss and joule loss of the motor are reduced, and the efficiency and the service life of the motor can be improved.

The chinese patent with the publication number CN111509925B discloses a flat wire motor stator plane hairpin molding device, which comprises two molding mechanisms symmetrically arranged left and right, wherein the molding mechanisms comprise molding die components and molding driving mechanisms, and the two molding die components symmetrically arranged left and right comprise: the device comprises a third pressure head, a second pressure head and a first pressure head, wherein forming grooves for placing straight flat wires are formed in the top surfaces of all the pressure heads. The forming driving mechanism is used for driving the forming die assembly to rotate around the rotating center so as to bend the middle of the flat wire, is also used for driving the pressing head to translate relative to the pressing head three so as to adjust the bending length of the middle bending section of the flat wire, and is used for driving the pressing head I to deflect relative to the pressing head II so as to bend the long straight leg of the flat wire. The forming device controls the movement of the pressure head through different executors, and the shape of the hairpin can be controlled by the executors for the hairpin with different shapes, so that the forming device has strong adaptability, universality and high working efficiency.

The technical scheme has the following defects:

the bending mode only carries out bending angle and length adjustment on the middle bending end of the copper wire to complete hairpin bending, the bending state is still the traditional 2D bending forming mode, but for the stator winding of the disc type flat wire motor, for the more complex winding mode, the copper wire is also required to be the 3D formed copper wire; meanwhile, the stamping structure has single function and does not have the characteristics of modularization and multiple operations.

Disclosure of Invention

The invention provides a three-dimensional forming tool and a process thereof for a hairclip wire for a disc motor, wherein the three-dimensional forming tool comprises a workbench, a stamping mechanism arranged on the workbench, a quick-change assembly arranged at the stamping mechanism, and a first module, a second module and a third module which are matched with the quick-change assembly;

the top of the workbench is fixedly provided with a fixing frame, the stamping mechanism comprises a press used for stamping, the press is fixedly arranged at the top end of the fixing frame, the press penetrates through the fixing frame and extends to the bottom of the fixing frame, and the output end of the press is fixedly provided with a pressure head;

the quick-change assembly comprises a mounting plate I and a mounting plate II, and the mounting plate I and the mounting plate II are respectively fixed at the bottom of the pressure head and the top of the workbench.

Through the technical scheme, the operation of 3D forming of the copper wire can be realized.

Further, the first module comprises a first upper pressing block and a first lower pressing block, a pressing groove for placing copper wires is formed in the side face of the first lower pressing block, and the bottom end of the first upper pressing block is a curved surface attached to the top end of the pressing groove;

the second module comprises a second upper pressing block, a second lower pressing block and a handle, wherein the upper surface of the second lower pressing block is fixedly provided with a lower forming block, the rear end of the upper surface of the lower forming block is provided with a lower forming groove, the left side of the upper surface of the lower forming block is provided with a chute, the upper surface of the lower forming block is fixedly provided with a plurality of limit teeth I for limiting copper wires, the front surface of the lower forming block is respectively hinged with symmetrical broken line blocks through two spring pins I, the two handles are respectively arranged at the front ends of the two broken line blocks, two broken line grooves matched with copper wires are respectively formed in the ends, far away from each other, of the two broken line blocks, the bottom surface of the second upper pressing block is fixedly provided with an upper forming block matched with the lower forming groove, the bottom end of the upper forming block is provided with two line pressing blocks, and the left side of the upper forming block is provided with a propping and tightening block matched with the chute;

the third module includes briquetting and third down, the bottom surface of briquetting is fixed with the top board on the third, the left and right sides of top board is fixed with first foot mould and second respectively and goes up the foot mould, the last fixed surface of third down the briquetting has the holding down plate, the left and right sides of holding down plate is fixed with first foot mould and the second foot mould of the foot mould looks adaptation on with first, the upper surface of briquetting is fixed with two respectively with first foot mould and second foot mould extension for planar placing block down, two the upper surface of placing block all is fixed with two spacing tooth II.

Through above-mentioned technical scheme, adopt the detachable structure of modularization, need not to change equipment when carrying out different punching operations, only need change different modules and can realize different punching press demands.

Further, a group of fastening blocks positioned on two sides are fixed at one ends of the mounting plate I and the mounting plate II, which are close to each other, each group of fastening blocks respectively form a T-shaped clamping groove, the two groups of fastening blocks are respectively movably clamped with the connecting ends of the first upper pressing block, the second upper pressing block, the third upper pressing block, the first lower pressing block, the second lower pressing block and the third lower pressing block, the front end of the mounting plate II is hinged with a front stop block through a spring pin II, and one end of the upper surface of the mounting plate II, which is far away from the front stop block, is fixed with a stop bar.

Through above-mentioned technical scheme for realize spacing and fixed work to different modules.

Further, the broken line block is trapezoid, and one side contacted with the copper wire is an inclined plane.

Through above-mentioned technical scheme, be convenient for bend the processing to the copper line, can avoid scraping simultaneously.

Further, the abutting block is trapezoid, and one side of the abutting block, which is contacted with the copper wire, is inclined.

Through above-mentioned technical scheme, the inside of conveniently inserting the chute is spacing to the copper line.

Further, the line pressing block and the abutting block are connected to the inside of a reset groove formed in the upper forming block through a first spring and a second spring respectively.

Through the technical scheme, reset operation after stamping stop can be realized through resilience of the spring.

Further, the left end and the right end of the pressure head are connected with the fixing frame through hydraulic rods.

Through the technical scheme, the pressure head is reinforced.

Further, the first upper pressing block and the first lower pressing block, the second upper pressing block and the second lower pressing block, and the third upper pressing block and the third lower pressing block are respectively provided with a sliding groove at the end far away from each other, and a sliding strip matched with the sliding grooves is fixed at the end, close to each other, of the mounting plate I and the mounting plate II.

Through above-mentioned technical scheme, the convenience is fixed a position when the installation to different modules, still has certain spacing effect simultaneously.

The invention further discloses a three-dimensional forming process of the hairpins for the disc motor, which comprises the three-dimensional forming tool of the hairpins for the disc motor, and further comprises the following steps:

s1, installing a first die, placing the copper wire formed by 3D in the first die, and stamping one pin of the 3D copper wire to obtain a copper wire formed at one time;

s2-1, replacing the first die with a second die, and carrying out secondary stamping on the copper wire formed at one time;

s2-2, bending two pins of the secondarily stamped copper wire to obtain a secondarily molded copper wire;

s3, replacing the second die with a third die, and respectively stamping two pins of the secondarily-formed copper wire to obtain a finally-formed copper wire;

s4, processing the finally formed copper wire into a disc type flat wire motor stator winding.

Compared with the prior art, the invention has the following beneficial effects:

1. the copper wire used in the more complex winding mode can be subjected to efficient 3D forming operation, the whole working flow is concise, and the operation of workers is convenient;

2. compared with traditional stamping equipment, the three-time stamping mode is adopted to realize the forming of the 3D copper wire, multiple stamping equipment is not needed at the same time, three modules which are modularized and detachable are adopted to carry out different stamping operations, so that the space of funds and a factory building is saved, the installation and the disassembly modes are simple and convenient while the efficient stamping effect is achieved, and the operation is easy to carry out.

Drawings

Fig. 1 is a perspective view of the present invention.

Fig. 2 is a schematic structural diagram of a quick-change assembly according to the present invention.

Fig. 3 is a perspective view of a first module according to the present invention.

Fig. 4 is a perspective view of a second module according to the present invention.

Fig. 5 is a perspective view of the second press block of the present invention in a rear view.

Fig. 6 is a perspective view of the first lower press block of the present invention in a rear view.

Fig. 7 is an exploded view of a first lower briquette according to the present invention.

Fig. 8 is a perspective view of a third module according to the present invention.

FIG. 9 is a schematic diagram illustrating the operation of the first upper and lower leg dies according to the present invention.

FIG. 10 is a schematic diagram illustrating the operation of the second upper and lower molds of the present invention.

Fig. 11 is a schematic view showing an operation state of the pressure tank of the present invention.

Fig. 12 is a schematic view of one-shot forming of copper wire in the present invention.

Fig. 13 is a schematic view of copper wire overmoulding in the present invention.

Fig. 14 is a schematic view of the final formation of copper wire in the present invention.

In the figure: 1. a work table; 2. a fixing frame; 31. a punching mechanism; 32. a pressure head; 4. copper wire; 5. a quick change assembly; 501. a mounting plate I; 502. a mounting plate II; 503. a fastening block; 504. a slide bar; 505. a front stop block; 506. a barrier strip; 6. a first module; 601. a first upper press block; 602. a first lower pressing block; 603. pressing a groove; 7. a second module; 701. a second upper press block; 702. a second press block; 703. a handle; 704. a lower molding groove; 705. a chute; 706. limiting teeth I; 707. a broken line block; 708. a folding groove; 709. an upper molding block; 710. a wire pressing block; 711. a tightening block; 712. a first spring; 713. a second spring; 714. a lower molding block; 8. a third module; 801. a third upper pressing block; 802. a third press block; 803. an upper press plate; 804. a first upper foot die; 805. a second upper foot die; 806. a lower pressing plate; 807. a first lower foot die; 808. a second lower leg mold; 809. placing a block; 810. and the limiting teeth II.

Detailed Description

In order to facilitate an understanding of the invention, the device of the invention will be described more fully below with reference to the accompanying drawings. Examples of the apparatus are given in the accompanying drawings. However, the apparatus may be embodied in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.

In the description of the present invention, it should be noted that, unless explicitly stated and limited otherwise, the terms "mounted," "connected," and "disposed" are to be construed broadly, and may be fixedly connected, disposed, or detachably connected, disposed, or integrally connected, disposed, for example. The specific meaning of the above terms in the present invention will be understood in specific cases by those of ordinary skill in the art.

Examples

As shown in fig. 1-10, the embodiment provides a three-dimensional forming tool and a process thereof for a hairclip wire for a disc motor, wherein the three-dimensional forming tool comprises a workbench 1, a stamping mechanism 31 arranged on the workbench 1, a quick-change assembly 5 arranged at the stamping mechanism 31, and a first module 6, a second module 7 and a third module 8 which are matched with the quick-change assembly 5;

the top of workstation 1 is fixed with mount 2, and stamping mechanism 31 is including the press that is used for the punching press, and press fixed mounting is in the top of mount 2, and the press runs through mount 2 and extends to its bottom, and the output fixed mounting of press has pressure head 32, and the left and right sides both ends of pressure head 32 all are connected with mount 2 through the hydraulic stem, can guarantee the certainty of motion trail when up-and-down motion, guarantee the degree of accuracy of punching press.

The quick-change assembly 5 comprises a mounting plate I501 and a mounting plate II502, the mounting plate I501 and the mounting plate II502 being fixed to the bottom of the ram 32 and the top of the table 1, respectively. The mounting panel I501 and mounting panel II502 are all fixed with a set of buckling blocks 503 that are located both sides that are close to each other, and every group buckling block 503 constitutes T font draw-in groove respectively, adopts slip male mode more convenient when three different modules are installed and changed to follow-up, and two groups buckling blocks 503 respectively with first last briquetting 601, second go up briquetting 701, third go up briquetting 801 and first lower briquetting 602, second lower briquetting 702, the link activity joint of third lower briquetting 802, and the front end of mounting panel II502 articulates through spring pin II has positive stop block 505, and the one end that positive stop block 505 was kept away from to mounting panel II502 upper surface is fixed with blend stop 506, is used for the spacing work to the back and forth position behind the three different modules respectively.

The first module 6 includes briquetting 601 and first briquetting 602 down on the first, the indent 603 that supplies copper line 4 to place has been seted up to the side of briquetting 602 down, briquetting 601 and first briquetting 602 down on the first, briquetting 701 and second briquetting 702 down on the second, the spout has all been seted up to the third one end that briquetting 801 and third briquetting 802 kept away from each other down, mounting panel I501 and mounting panel II502 one end that is close to each other are fixed with the draw runner 504 with spout looks adaptation, accomplish the location when installing to three different modules, the bottom of briquetting 601 is the curved surface that laminates with the top of indent 603 down for the punching press to copper line 4.

The second module 7 comprises a second upper pressing block 701, a second lower pressing block 702 and a handle 703, wherein a lower forming block 714 is fixed on the upper surface of the second lower pressing block 702, a lower forming groove 704 is formed in the rear end of the upper surface of the lower forming block 714, a chute 705 is formed in the left side of the upper surface of the lower forming block 714, a plurality of limiting teeth I706 for limiting the copper wire 4 are fixed on the upper surface of the lower forming block 714, symmetrical broken line blocks 707 are hinged to the front surface of the lower forming block 714 through two spring pins I respectively, the broken line blocks 707 are trapezoid, and one side contacted with the copper wire 4 is inclined. The two handles 703 are respectively mounted at the front ends of the two fold line blocks 707, and fold line grooves 708 matched with the copper wire 4 are respectively formed at the ends of the two fold line blocks 707, which are far away from each other, so as to realize the purpose of deflecting the two pins of the copper wire 4. The bottom surface of the second upper pressing block 701 is fixed with an upper forming block 709 matched with the lower forming groove 704, two line pressing blocks 710 are arranged at the bottom end of the upper forming block 709, a supporting block 711 matched with the chute 705 is arranged at the left side of the upper forming block 709, the supporting block 711 is trapezoid, one side contacted with the copper wire 4 is inclined, and the copper wire 4 is conveniently inserted into the chute 705 to limit the position. The pressing block 710 and the pressing block 711 are connected to the inside of a reset groove formed in the upper molding block 709 through a first spring 712 and a second spring 713, respectively, and can be retracted and buffered during the downward-moving stamping operation, and can be reset after the stamping operation is completed. The wire pressing block 710 is in contact with the copper wire 4 in advance, so that the purpose of pre-pressing is achieved, and the abutting block 711 slides into the chute 705 in the process of continuing to move downwards, so that the copper wire 4 is further fixed.

The third module 8 includes a third upper pressing block 801 and a third lower pressing block 802, an upper pressing plate 803 is fixed on the bottom surface of the third upper pressing block 801, a first upper pin die 804 and a second upper pin die 805 are respectively fixed on the left side and the right side of the upper pressing plate 803, a lower pressing plate 806 is fixed on the upper surface of the third lower pressing block 802, a first lower pin die 807 and a second lower pin die 808 which are matched with the first upper pin die 804 and the second upper pin die 805 are respectively fixed on the left side and the right side of the lower pressing plate 806, and are respectively and correspondingly arranged for respectively punching two pins of the copper wire 4. The upper surface of the lower pressing block is fixedly provided with two placing blocks 809 which respectively extend the first lower leg die 807 and the second lower leg die 808 into planes, the upper surfaces of the two placing blocks 809 are fixedly provided with two limiting teeth II810, and the two limiting teeth II and the limiting teeth I706 have the same function, so that the copper wire 4 is subjected to limiting treatment, and a smooth bolt column can be adopted for replacement.

It should be noted that, the side of the first upper pin die 804 and the first lower pin die 807 close to the copper wire 4, and the side of the second upper pin die 805 and the second lower pin die 808 close to the copper wire 4 are also provided with a certain cambered surface, so that the other pin of the copper wire 4 is punched into a required cambered surface.

The three-dimensional forming process of the hairpins for the disc motor is also described, and the three-dimensional forming tool of the hairpins for the disc motor comprises the following steps of:

s1, firstly, a first die is installed, left and right limiting is completed by inserting a first upper pressing block 601 and a first lower pressing block 602 into a T-shaped clamping groove formed by two groups of fastening blocks 503, front and rear limiting is completed by a baffle strip 506 and a rotary front stop block 505, a 2D formed copper wire 4 is placed at a pressing groove 603, and a press driving press head 32 drives the first upper pressing block 601 to move downwards to punch one pin of the 2D copper wire 4, so that a one-time formed copper wire 4 is obtained (as shown in figure 12);

s2-1, replacing the first die with a second die (after the press is reset, the front stop block 505 is reversed, the first die is taken down, then the second upper pressing block 701 and the second lower pressing block 702 are installed in the same installation mode as in the step S1, the press drives the second upper pressing block 701 to enable the upper forming block 709 to move towards the lower forming groove 704, and the copper wire 4 formed at one time is punched for the second time);

s2-2, pulling two handles 703 by a worker (the handles 703 can also be automatically adjusted by connecting automatic equipment and can be determined according to actual production conditions), and bending two pins of the copper wire 4 subjected to secondary punching on the outer side by two fold line blocks 707 at a certain angle according to requirements to obtain a secondary formed copper wire 4 (shown in fig. 13);

s3, replacing the second die with a third die (the same as the disassembling step of the step S2-1, replacing an installation object with a third upper pressing block 801 and a third lower pressing block 802), driving the third upper pressing block 801 to move downwards through a press, and respectively punching two pins of the secondarily molded copper wire 4 through a first lower pin die 807 and a second lower pin die 808 by a first upper pin die 804 and a second upper pin die 805 to obtain a finally molded copper wire 4 (shown in fig. 14);

s4, processing the finally formed copper wire 4 into a disc type flat wire motor stator winding.

It should be noted that the structure of the present invention may be implemented in many different forms, and is not limited to the embodiments, and any equivalent transformation made by those skilled in the art using the present specification and the accompanying drawings, or direct or indirect application in other related technical fields, such as loading and unloading of other articles, are included in the protection scope of the present invention.

Claims (9)

1. The utility model provides a three-dimensional shaping frock of hairpin line for disc motor, includes three-dimensional shaping frock, its characterized in that: the three-dimensional forming tool comprises a workbench, a stamping mechanism arranged on the workbench, a quick-change assembly arranged at the stamping mechanism, and a first module, a second module and a third module which are matched with the quick-change assembly;

the top of the workbench is fixedly provided with a fixing frame, the stamping mechanism comprises a press used for stamping, the press is fixedly arranged at the top end of the fixing frame, the press penetrates through the fixing frame and extends to the bottom of the fixing frame, and the output end of the press is fixedly provided with a pressure head;

the quick-change assembly comprises a mounting plate I and a mounting plate II, and the mounting plate I and the mounting plate II are respectively fixed at the bottom of the pressure head and the top of the workbench.

2. The stereoscopic shaping tool for hairpins for disc motors as claimed in claim 1, wherein: the first module comprises a first upper pressing block and a first lower pressing block, a pressing groove for placing copper wires is formed in the side face of the first lower pressing block, and the bottom end of the first upper pressing block is a curved surface attached to the top end of the pressing groove;

the second module comprises a second upper pressing block, a second lower pressing block and a handle, wherein the upper surface of the second lower pressing block is fixedly provided with a lower forming block, the rear end of the upper surface of the lower forming block is provided with a lower forming groove, the left side of the upper surface of the lower forming block is provided with a chute, the upper surface of the lower forming block is fixedly provided with a plurality of limit teeth I for limiting copper wires, the front surface of the lower forming block is respectively hinged with symmetrical broken line blocks through two spring pins I, the two handles are respectively arranged at the front ends of the two broken line blocks, two broken line grooves matched with copper wires are respectively formed in the ends, far away from each other, of the two broken line blocks, the bottom surface of the second upper pressing block is fixedly provided with an upper forming block matched with the lower forming groove, the bottom end of the upper forming block is provided with two line pressing blocks, and the left side of the upper forming block is provided with a propping and tightening block matched with the chute;

the third module includes briquetting and third down, the bottom surface of briquetting is fixed with the top board on the third, the left and right sides of top board is fixed with first foot mould and second respectively and goes up the foot mould, the last fixed surface of third down the briquetting has the holding down plate, the left and right sides of holding down plate is fixed with first foot mould and the second foot mould of the foot mould looks adaptation on with first, the upper surface of briquetting is fixed with two respectively with first foot mould and second foot mould extension for planar placing block down, two the upper surface of placing block all is fixed with two spacing tooth II.

3. The stereoscopic shaping tool for hairpins for disc motors as claimed in claim 2, wherein: the mounting panel I and mounting panel II all are fixed with a set of fastening piece that is located both sides that is close to each other, and every group fastening piece constitutes T font draw-in groove respectively, and two sets of fastening pieces respectively with first last briquetting, second go up briquetting, third go up briquetting and first briquetting, second down briquetting, the link activity joint of briquetting under the third, and mounting panel II's front end has the positive stop through spring pin II articulated, and mounting panel II upper surface is kept away from the one end of positive stop and is fixed with the blend stop.

4. The stereoscopic shaping tool and the process of the hairclip wire for the disc motor as claimed in claim 2, wherein: the broken line block is trapezoid, and one side contacted with the copper wire is an inclined plane.

5. The stereoscopic shaping tool for hairpins for disc motors as claimed in claim 2, wherein: the abutting block is trapezoid, and one side of the abutting block, which is contacted with the copper wire, is inclined.

6. The stereoscopic shaping tool for hairpins for disc motors as claimed in claim 2, wherein: the line pressing block and the abutting block are connected to the inside of a reset groove formed in the upper forming block through a first spring and a second spring respectively.

7. The stereoscopic shaping tool for hairpins for disc motors as claimed in claim 1, wherein: the left end and the right end of the pressure head are connected with the fixing frame through hydraulic rods.

8. The stereoscopic shaping tool for hairpins for disc motors as claimed in claim 2, wherein: the sliding grooves are formed in the ends, far away from each other, of the first upper pressing block, the first lower pressing block, the second upper pressing block, the second lower pressing block, the third upper pressing block and the third lower pressing block, and sliding strips matched with the sliding grooves are fixed at the ends, close to each other, of the mounting plates I and II.

9. A three-dimensional molding process of a hairclip wire for a disc motor is characterized in that: a stereolithography tool comprising the hairclip wire for a disc motor according to any one of claims 1 to 8, further comprising the steps of:

s1, installing a first die, placing a 2D formed copper wire in the first die, and stamping one pin of the 2D copper wire to obtain a one-step formed copper wire;

s2-1, replacing the first die with a second die, and carrying out secondary stamping on the copper wire formed at one time;

s2-2, bending two pins of the secondarily stamped copper wire to obtain a secondarily molded copper wire;

s3, replacing the second die with a third die, and respectively stamping two pins of the secondarily-formed copper wire to obtain a finally-formed copper wire;

s4, processing the finally formed copper wire into a disc type flat wire motor stator winding.