KR102263180B1 - Dual cnc type hairpin manufacturing apparatus - Google Patents

Abstract

According to an embodiment of the present disclosure, a hairpin manufacturing apparatus for an electric motor comprises: a cutting unit configured to cut the metal wire supplied along a first axis at every predetermined length; a distributor configured to alternately supply the cut metal wire to a first forming device and a second forming device; the first forming device configured to form a first three-dimensional (3D) hairpin structure using the cut metal wire supplied from the distributor; the second forming device configured to form a second 3D hairpin structure using the cut metal wire supplied from the distributor; and a control unit configured to control operations of the cutting unit, the distributor, the first forming device and the second forming device.

Description

Dual CNC type hairpin manufacturing equipment {DUAL CNC TYPE HAIRPIN MANUFACTURING APPARATUS}

The present disclosure relates to a dual CNC type hairpin manufacturing apparatus, and more particularly, to an apparatus for manufacturing a hairpin by processing a metal wire.

The efficiency of a motor driving an electric vehicle (hereinafter referred to as EV) is a concept corresponding to the fuel efficiency of an internal combustion engine vehicle. Therefore, the efficiency of the driving motor is one of the important indicators directly related to the performance of the EV. Recently, as a method for increasing the efficiency of a driving motor, a technology for reducing copper loss, which accounts for the largest energy loss in the motor, is attracting attention.

One of the effective methods for reducing copper loss is a technology to improve the space factor of the stator winding. The space factor indicates the proportion of the windings in the area of the stator slot. If the space factor is increased, the current density of the stator winding decreases under the same load condition, thereby reducing copper loss. However, due to the increase in the space factor, the adverse effect of increasing the proportion of defective windings occurs, and the hairpin method is rapidly spreading in the EV industry to solve this problem.

In the hairpin method, a copper wire is molded into a hairpin shape, inserted into a slot, and then welded. By using the hairpin method, it is possible to reduce the waste of space between the coils, thereby maximizing the space factor. The hairpin method is advantageous in terms of efficiency and power density of the driven motor, but has a problem in that the manufacturing process is complicated and quality control is difficult.
The technology that is the background of the present invention is disclosed in Japanese Patent Publication No. 5955142 (June 24, 2016), Korean Patent Application Laid-Open No. 10-2007-0120564 (December 24, 2007), and Korean Patent Application Laid-Open No. 10-2016- It is disclosed in 0131056 (2016.11.15.) and Korean Patent Laid-Open No. 10-2017-0066859 (2017.06.15.).

Embodiments disclosed herein provide an apparatus capable of reducing the time required for producing a hairpin by manufacturing a hairpin for an electric motor through a forming part and a pressing part.

A hairpin manufacturing apparatus for an electric motor according to an embodiment of the present disclosure includes a cutting unit configured to cut a metal wire supplied along a first axis for every predetermined length, and a first forming apparatus and a second forming apparatus for the cut metal wire. A distributor configured to alternately supply, a first forming device configured to form a first three-dimensional hairpin structure using the cut metal wire supplied from the distributor, and a second three-dimensional hairpin structure using the cut metal wire supplied from the distributor and a second forming device configured to: and a control section configured to control the operation of the cutting unit, the dispenser, the first forming device and the second forming device.

According to one embodiment, the apparatus for manufacturing a hairpin further comprises at least one rail guiding the dispenser to move between a first position and a second position along a second axis orthogonal to the first axis, wherein the control unit comprises: When in the first position, the distributor is controlled so that the cut metal wire is provided to the second forming apparatus, and when the distributor is in the second position, the distributor is controlled so that the cut metal wire is provided to the first forming apparatus.

According to an embodiment, the first forming apparatus includes a first metal wire supply unit configured to deliver the cut metal wire supplied from the distributor to the first forming unit along a first axis, and a cut metal wire supplied from the first metal wire supply unit. a first molding part configured to bend to form a first two-dimensional hairpin structure and a first press part configured to press the first two-dimensional hairpin structure molded by the first molding part to form a first three-dimensional hairpin structure; The second forming apparatus includes a second metal wire supply unit configured to transmit the cut metal wire supplied from the distributor to the second forming unit along a first axis, and a second two-dimensional hairpin by bending the cut metal wire supplied from the second metal wire supply unit. and a second molding portion configured to form a structure and a second press portion configured to press the second two-dimensional hairpin structure molded by the second molding portion to form a second three-dimensional hairpin structure.

According to an embodiment, the apparatus for manufacturing a hairpin includes a first robot arm configured to move a first two-dimensional hairpin structure formed by the first forming unit to the first press unit and a second two-dimensional hairpin structure formed by the second forming unit. It further includes a second robot arm configured to move to the second press unit.

According to an embodiment, the control unit bends the cut metal wire supplied from the first metal wire supply unit to form a first two-dimensional hairpin structure in which the first U-bending part, the V-bending part, and the second U-bending part are sequentially formed. Control the first shaping part, control the first robot arm to move the first two-dimensional hairpin structure to the first press part, and press the first two-dimensional hairpin structure to form a first three-dimensional hairpin structure including the R bending part Controlling the first press unit and bending the cut metal wire supplied from the second metal wire supply unit to form a second two-dimensional hairpin structure in which the first U bending unit, the V bending unit, and the second U bending unit are sequentially formed. controlling the part, controlling the second robot arm to move the second two-dimensional hairpin structure to the second pressing part, and pressing the second two-dimensional hairpin structure to form a second three-dimensional hairpin structure including the R bending part. Control.

According to an embodiment, the first forming part may include a first bending device including a first bending member and a second bending member, and a first driving part configured to move the first bending device in a second axial direction orthogonal to the first axis. , a second driving unit configured to move the bending device in a third axial direction perpendicular to the first axis and the second axis, wherein the second forming unit includes a third bending member and a fourth bending member. , a third driving unit configured to move the second bending device in a second axial direction perpendicular to the first axis, and a fourth driving unit configured to move the second bending device in a third axial direction orthogonal to the first axis and the second axis. and wherein the first bending member, the second bending member, the third bending member, and the fourth bending member extend along the third axis.

According to an embodiment, the controller is configured to move the first bending device in the second axial direction to form a first two-dimensional hairpin structure in which the first U-bending part, the V-bending part, and the second U-bending part are sequentially formed. In order to control the first driving unit or to form a first two-dimensional hairpin structure in which the first U bending unit, the V bending unit, and the second U bending unit are sequentially formed, the second driving unit may be configured to move the first bending device in the third axial direction. Control.

According to an embodiment, the first press unit may include a first upper frame including a first protrusion, a first lower frame including a first concave portion and facing the first upper frame, and a first upper frame or a first lower frame. a fifth driving unit configured to move at least one in a third axial direction, wherein the control unit is configured to place the first two-dimensional hairpin structure molded by the first forming unit within the first concave portion of the first lower frame. The arm is controlled, and the fifth driving unit is controlled to press the first two-dimensional hairpin structure into the first protrusion and the first concave portion to form a first three-dimensional hairpin structure including the R-bending portion.

According to an embodiment, the first press unit rotates about a central axis of rotation and a second upper frame including a second protrusion, a second lower frame including a second concave portion and opposing the second upper frame, and the first press unit It further comprises a sixth driving unit configured to make the motor rotate, the central axis of rotation is parallel to the third axis, and the control unit selects one of the first upper frame and the first lower frame, or the second upper frame and the second lower frame, and selects the second 1 Controls the sixth driving unit to press the two-dimensional hairpin structure.

According to an embodiment, the first upper frame and the first lower frame face the second upper frame and the second lower frame with a central axis of rotation therebetween.

According to various embodiments of the present disclosure, by forming a two-dimensional hairpin structure in the forming part and forming a three-dimensional hairpin structure in the pressing part, the time required for generating the hairpin may be reduced. For this reason, it is possible to lower the manufacturing cost of the hairpin. In addition, by moving the bending device through a plurality of stages to bend a metal wire to manufacture a hairpin, the structure and driving algorithm of the hairpin manufacturing device may be further simplified. Due to this, it is possible to lower the price of the hairpin manufacturing equipment, and to reduce the maintenance and repair cost.

According to various embodiments of the present disclosure, by alternately supplying the cut metal wire to the first forming device and the second forming device by supplying the cut metal wire to the forming device while gripping the metal wire through the distributor, forming, The time required for manufacturing the hairpin can be minimized by minimizing the time required for generating the additional two-dimensional hairpin structure, the time for cutting the metal wire, and the waiting time between the time for moving the cut metal wire to the forming apparatus.

According to various embodiments of the present disclosure, by manufacturing a hairpin using a press unit including a plurality of pairs of upper and lower molds, hairpin structures having various shapes can be quickly formed.

According to various embodiments of the present disclosure, by bending the metal wire using a forming part including two bending members and three driving parts, a metal wire of various sizes and thicknesses may be bent to a desired shape/angle.

The effects of the present disclosure are not limited to the effects mentioned above, and other effects not mentioned will be clearly understood by those skilled in the art from the description of the claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present disclosure will be described with reference to the accompanying drawings described below, wherein like reference numerals denote like elements, but are not limited thereto.
1 is a block diagram of equipment for forming and aligning a hairpin according to an embodiment of the present disclosure;
2 is a detailed block diagram of a feeding device according to an embodiment of the present disclosure.
3 is a detailed block diagram of a first molding apparatus according to an embodiment of the present disclosure.
4 is a perspective view of a hairpin manufacturing apparatus according to an embodiment of the present disclosure.
5 is a view illustrating an example in which a metal wire cut by a distributor according to an embodiment of the present disclosure is provided as a first forming part or a second forming part.
6 is a perspective view of a first molding part according to an embodiment of the present disclosure;
7 is a view illustrating an example of bending a metal wire using a first bending member according to an embodiment of the present disclosure.
8 is a perspective view of a two-dimensional hairpin structure formed according to an embodiment of the present disclosure.
9 is a top view of the first press unit according to an embodiment of the present disclosure.
10 is a perspective view of a pair of upper and lower frames according to an embodiment of the present disclosure;
11 is a top view of the first press unit according to another embodiment of the present disclosure.
12 is a perspective view illustrating a two-dimensional hairpin structure and a three-dimensional hairpin structure formed according to an exemplary embodiment of the present disclosure.

Hereinafter, specific contents for carrying out the present disclosure will be described in detail with reference to the accompanying drawings. The present application may be embodied in several different forms and is not limited to the embodiments described herein. In the following description, if there is a risk of unnecessarily obscuring the subject matter of the present disclosure, detailed descriptions of well-known functions or configurations will be omitted.

In the accompanying drawings, identical or corresponding components may be assigned the same reference numerals. In addition, in the description of the embodiments below, overlapping description of the same or corresponding components may be omitted. However, even if descriptions regarding components are omitted, it is not intended that such components are not included in any embodiment.

The terms used in this specification are selected as currently widely used general terms as possible while considering the functions in the present disclosure, but may vary depending on the intention or precedent of a person skilled in the art, the emergence of new technology, and the like. In addition, in a specific case, there is a term arbitrarily selected by the applicant, and in this case, the meaning will be described in detail in the description of the corresponding invention. Therefore, the terms used in the present disclosure should be defined based on the meaning of the term and the contents of the present disclosure, rather than the simple name of the term.

References in the singular herein include plural expressions unless the context clearly dictates that the singular is singular. Also, the plural expression includes the singular expression unless the context clearly dictates the plural.

In the entire specification, when a part "includes" a certain component, it means that other components may be further included, rather than excluding other components, unless otherwise stated.

Advantages and features of the disclosed embodiments, and methods of achieving them, will become apparent with reference to the embodiments described below in conjunction with the accompanying drawings. However, the present disclosure is not limited to the embodiments disclosed below, but may be implemented in various different forms, and only the present embodiments allow the present disclosure to be complete, and those of ordinary skill in the art to which the present disclosure pertains. It is only provided to fully inform the person of the scope of the invention.

Before describing the embodiments of the present disclosure in detail, the upper side of the drawing may be referred to as “upper” or “upper side” and the lower side as “lower” or “lower side” of the configuration shown in the drawing. In addition, in the drawings, the remaining portions between the upper and lower portions or the upper and lower portions of the illustrated configuration may be referred to as “side” or “side”.

In embodiments of the present disclosure, the left side of a drawing may be referred to as “left” or “left”, and the right side may be referred to as “right” or “right” of the configuration shown in the drawing. Relative terms such as "upper", "upper", etc. may be used to describe the relationship between the components shown in the drawings, and the present disclosure is not limited by such terms.

Reference to "A and/or B" in this specification means A, or B, or A and B.

In the present disclosure, "first axial direction" may refer to a direction in which the metal wire moves or an opposite direction. Also, the “second axis direction” may refer to a direction perpendicular to the first axis and parallel to the ground. Additionally, “third axis direction” may refer to a direction orthogonal to the first axis and the second axis, ie, a direction orthogonal to the ground. The first axis, the second axis, and the third axis may be referred to as an x axis, a y axis, and a z axis, respectively.

1 is a block diagram of equipment for forming and aligning a hairpin according to an embodiment of the present disclosure; As shown, the equipment for forming and aligning the hairpin is a decal device 110 , a peeling device 120 , a feeding device 130 , a first shaping device 140 , a second shaping device 150 , and a first alignment A device 160 and a second alignment device 170 may be included. The decal device 110 may be a device for removing bending, bending, etc. that may exist in the metal wire released from the supply reel. In one embodiment, the metal wire may be a square copper wire having a square cross section.

The stripping device 120 is a device for removing the insulating coating surrounding the metal wire. In one embodiment, the stripping device 120 may remove a portion of the insulating coating (eg, enamel) coated on the metal wire. For example, the peeling device 120 may remove the insulating coating on the metal wire by using a peeling skin such as a blade or a laser.

The feeding device 130 may be a device for supplying the metal wire that has passed through the decal device 110 and the stripping device 120 to the forming device. In one embodiment, the feeding device 130 may cut the metal wire that has passed through the stripping device 120 , and alternately supply the cut metal wire to the first molding device 140 and the second molding device 150 . . The feeding apparatus 130 may provide the metal wire to the first forming apparatus 140 or the second forming apparatus 150 at a rate suitable for a process for forming the metal wire. In addition, the feeding device 130 may adjust the supply and interruption of the metal wire according to the state of the first shaping device 140 or the second shaping device 150 , and may variably control the supply speed of the metal wire. .

The first forming apparatus 140 and the second forming apparatus 150 may respectively form a three-dimensional hairpin structure using the metal wire supplied from the feeding apparatus 130 . Specifically, the first forming apparatus 140 and the second forming apparatus 150 each bend the metal wire supplied from the feeding apparatus 130 to form a two-dimensional hairpin structure, and press the formed two-dimensional hairpin structure to form a three-dimensional hairpin structure. It can be formed into a dimensional hairpin structure.

The formed three-dimensional hairpin structure may be moved to an alignment device using a robot arm or the like. The alignment device may be a device that aligns the formed hairpins (ie, a three-dimensional hairpin structure) for insertion into the stator core. According to one embodiment, the alignment device is to the first alignment device 160 and the second molding device 150 configured to align the three-dimensional hairpin structure formed by the first molding device 140 for insertion into the stator core. and a second alignment device 170 configured to align the three-dimensional hairpin structure formed by the stator for insertion into the stator core. The aligned hairpins may be inserted into the stator core. That is, the hairpins aligned by the first alignment device 160 may be inserted into the first stator core, and the hairpins aligned by the second alignment device 170 may be inserted into the second stator core. Alternatively, the three-dimensional hairpin structures formed by the first shaping device 140 and the second shaping device 150 may be aligned by one alignment device and inserted into one stator core.

2 is a detailed block diagram of the feeding device 130 according to an embodiment of the present disclosure. The hairpin manufacturing apparatus may include a peeling device 120 , a feeding device 130 , a first molding device 140 , and a second molding device 150 . As shown, the feeding device 130 may include a cutting unit 210 and a distributor 220 .

The cutting unit 210 may be a device for cutting the metal wire supplied along the first axis for each predetermined length. For example, the operation of the cutting unit 210 may be controlled by the control unit to adjust the length to cut the metal wire supplied from the stripping device 120 . The metal wire cut by the cutting unit 210 may have different lengths depending on the type of electric motor to be produced.

The distributor 220 may alternately supply the metal wire cut to a predetermined length by the cutting unit 210 to the first forming apparatus 140 and the second forming apparatus 150 . According to an embodiment, the distributor 220 may hold the metal wire before the cutting unit 210 cuts the metal wire. When the cutting unit 210 cuts the metal wire while the distributor 220 holds the metal wire, the distributor 220 provides the cut metal wire to the first molding device 140 or the second molding device 150 . can do. The first forming apparatus 140 and the second forming apparatus 150 receiving the cut metal wire may form a three-dimensional hairpin structure, respectively.

3 is a detailed block diagram of the first molding apparatus 140 according to an embodiment of the present disclosure. The first forming apparatus 140 may include a first metal wire supply unit 310 , a first forming unit 320 , and a first press unit 330 . The first metal wire supply unit 310 may be a device for supplying the cut metal wire provided from the distributor 220 of the feeding device 130 to the first forming unit 320 . In one embodiment, the first metal wire supply unit 310 provides the cut metal wire to the first forming unit 320 at a speed suitable for a process for forming the cut metal wire in the first forming unit 320 . can In addition, the first metal wire supply unit 310 may control the supply and interruption of the cut metal wire according to the state of the first forming part 320 , and may variably control the supply speed of the cut metal wire.

The first forming unit 320 may be a device for forming a two-dimensional hairpin structure by bending the cut metal wire supplied from the first metal wire supply unit 310 . For example, the first forming part 320 may bend the cut metal wire to form a two-dimensional hairpin structure in which the first U-bending part, the V-bending part, and the second U-bending part are sequentially formed. The two-dimensional hairpin structure formed by the first molding unit 320 may have a different shape depending on the type of electric motor to be produced.

The first press unit 330 may be a device for forming a three-dimensional hairpin structure using the two-dimensional hairpin structure formed by the first forming unit 320 . According to an embodiment, the first molding apparatus 140 may further include a first robot arm (not shown). The first robot arm (not shown) may move the two-dimensional hairpin structure molded by the first forming unit 320 to the first pressing unit 330 . The first press unit 330 provided with the two-dimensional hairpin structure from the first robot arm (not shown) may press the two-dimensional hairpin structure to form a three-dimensional hairpin structure in which the R bending part is formed.

The two-dimensional hairpin structure may be pressed by the first press unit 330 to have different R bending shapes depending on the type of the electric motor. To this end, the first press unit 330 may include a plurality of pairs of upper and lower frames corresponding to the plurality of R bending shapes. In this case, the first press unit 330 may press the two-dimensional hairpin structure using one of a plurality of pairs of upper and lower molds to form a three-dimensional hairpin structure.

The hairpin manufacturing apparatus may further include a robot arm for moving the three-dimensional hairpin structure formed by the press unit from the first press unit 330 to the first alignment device 160 . According to one embodiment, the hairpin manufacturing apparatus includes a third robot arm (not shown) for moving the three-dimensional hairpin structure formed by the first press unit 330 from the first press unit 330 to the first alignment device 160 . city) may be included. In another embodiment, the hairpin manufacturing apparatus moves the two-dimensional hairpin structure molded by the first forming unit 320 to the first pressing unit 330 using the first robot arm, and the first pressing unit 330 . The three-dimensional hairpin structure formed by the may be moved from the first press unit 330 to the first alignment device 160 .

The above-described configuration of the first molding apparatus 140 may be equally applied to the second molding apparatus 150 . In one embodiment, the second forming device 150 is a second metal wire supply unit for supplying the cut metal wire provided from the distributor 220 of the feeding device 130 to the second forming unit, from the second metal wire supply unit. A second forming unit for bending the supplied cut metal wire to form a two-dimensional hairpin structure, a second robot arm for moving the two-dimensional hairpin structure formed by the second forming unit to a second press unit, and a second forming unit A second press unit for forming a three-dimensional hairpin structure using the two-dimensional hairpin structure molded by the unit and a second press unit for moving the three-dimensional hairpin structure formed by the second press unit from the second press unit to the second alignment device A fourth robot arm may be included.

In FIG. 3 , the first robot arm and the third robot arm move the two-dimensional hairpin structure and the three-dimensional hairpin structure molded by the first molding device 140 to manufacture a hairpin, and a two-dimensional hairpin molded by the second molding device. The structure and the three-dimensional hairpin structure have been described above that the second robot arm and the fourth robot arm move to manufacture the hairpin, but the present invention is not limited thereto. The number of robot arms can be changed as needed. In one embodiment, the hairpin manufacturing apparatus includes a first robot arm and a second robot arm for moving the two-dimensional hairpin structure formed by the first forming part 320 or the second forming part to the first pressing part 330 or the second pressing part. A second robot arm for moving the three-dimensional hairpin structure formed from the first press unit 330 or the second press unit to the first alignment device 160 or the second alignment device may be included.

That is, while the first forming unit 320 bends the cut metal wire to form the two-dimensional hairpin structure, the first robot arm moves the two-dimensional hairpin structure formed by the second forming unit to the second press unit, , while the second forming unit bends the cut metal wire to form the two-dimensional hairpin structure, the first robot arm converts the two-dimensional hairpin structure formed by the first forming unit 320 to the first press unit 330 . can be moved In addition, while the first press unit 330 presses the 2D hairpin structure provided from the first molding unit 320 to form the 3D hairpin structure, the 3D hairpin formed by the second press unit The three-dimensional hairpin formed by the first press unit 330 while the structure is moved to the second alignment device and the second press unit presses the two-dimensional hairpin structure provided from the second forming unit to form the three-dimensional hairpin structure. The structure may be moved to the first alignment device 160 .

4 is a perspective view of a hairpin manufacturing apparatus 400 according to an embodiment of the present disclosure. According to an embodiment, the hairpin manufacturing apparatus 400 includes a cutting unit 210 , a distributor 220 , a first metal wire supply unit 310 , a first molding unit 320 , a second metal wire supply unit 410 , and a second metal wire supply unit 410 . Two forming parts 420 may be included. As illustrated, the first forming part 320 may include a first bending device 430 .

The cutting unit 210 may be configured to cut the partially stripped metal wire supplied along the first axis (ie, the x-axis parallel to the ground) for every predetermined length. The controller may control the operation of the cutting unit 210 so that the metal wire cut by the cutting unit 210 may have different lengths according to the type of electric motor to be produced. For example, the cutting unit 210 may adjust the timing of cutting the rapid wire rod so that the cut metal wire has a different length depending on the type of electric motor to be produced. Alternatively, the cutting unit 210 may be moved in the x-axis direction by a driving unit (not shown) to cut the metal wire so that the cut metal wire has a different length depending on the type of electric motor to be produced.

The distributor 220 is The metal wire cut by the cutting unit 210 may be alternately supplied to the first metal wire supply unit 310 and the second metal wire supply unit 410 . According to an embodiment, the distributor 220 may include a driving unit (not shown) configured to move the distributor 220 in the y-axis direction. The controller may control the operation of the driving unit (not shown) so that the distributor 220 alternately supplies the cut metal wire to the first metal wire supply unit 310 and the second metal wire supply unit 410 . For example, the distributor 220 supplies the cut metal wire to the first metal wire supply unit 310 , and then moves in the y-axis direction by a driving unit (not shown) to the second metal wire supply unit 410 . It is possible to supply the cut metal wire.

The first metal wire supply unit 310 may provide the cut metal wire supplied from the distributor 220 to the first molding unit 320 by moving it along the x-axis direction. Similarly, the second metal wire supply unit 410 may provide the cut metal wire supplied from the distributor 220 to the second molding unit 420 by moving it along the x-axis direction. In an embodiment, the first metal wire supply unit 310 and the second metal wire supply unit 410 may have a symmetrical structure with respect to the cutting unit 210 and/or the distributor 220 .

The first molding unit 320 may be configured to form a two-dimensional hairpin structure using the cut metal wire supplied from the first metal wire supply unit 310 . Similarly, the second forming unit 420 may be configured to form a two-dimensional hairpin structure using the cut metal wire supplied from the second metal wire supply unit 410 . In an embodiment, the first molding part 320 and the second molding part 420 may have a symmetrical structure with respect to the cut part 210 and/or the distributor 220 .

According to an exemplary embodiment, the first forming part 320 may move the first bending device 430 and the first bending device 430 in the direction of the second axis (ie, the y-axis parallel to the ground) perpendicular to the x-axis. A first driving unit (not shown) configured to move, a first bending device 430 configured to move in a third axis (ie, z axis orthogonal to the ground) direction perpendicular to the first axis and the second axis 2 may include a driving unit (not shown). The controller may control the operation of the first driving unit (not shown) and/or the second driving unit (not shown) so that the first bending device 430 bends the cut metal wire to form a two-dimensional hairpin structure.

As illustrated, the first bending device 430 may include a first bending member 432 and a second bending member 434 configured to bend the metal wire. According to an embodiment, the first bending member 432 and the second bending member 434 may have a shape extending along the z-axis, and the second bending member 434 may have a flat upper surface (xy plane). have. In an embodiment, the first bending device 430 may bend the cut metal wire using the first bending member 432 while moving in the y-axis to form a two-dimensional hairpin structure. In another embodiment, the first bending device 430 may bend the cut metal wire using the second bending member 434 while moving in the z-axis to form a two-dimensional hairpin structure. The second bending device may have the same configuration as the first bending device 430 .

In an embodiment, the first bending device 430 may move in the y-axis direction by a first driving unit (not shown) to bend the metal wire to form a two-dimensional hairpin structure. Here, the first driver (not shown) may move the first bending device 430 in the y-axis direction based on a control signal from the controller. When the first bending device 430 is located under the metal wire, the control unit controls the operation of the second driving unit (not shown) to move the first bending device 430 in the z-axis direction to move the first bending member ( 432) may be positioned on the side of the metal wire. Additionally or alternatively, the first bending device 430 may move in the z-axis direction by a second driving unit (not shown) to bend the cut metal wire to form a two-dimensional hairpin structure.

When the metal wire cut by the first bending device 430 is bent to form a two-dimensional hairpin structure, the first robot arm (not shown) generates a two-dimensional hairpin structure formed by gripping a portion of the two-dimensional hairpin structure. 1 It can be moved by a press unit (not shown). For example, the first robot arm (not shown) may hold a portion of the two-dimensional hairpin structure formed by the first molding unit 320 including the tongs. Similarly, when the metal wire cut by the second bending device is bent to form a two-dimensional hairpin structure, the second robot arm (not shown) grips a portion of the two-dimensional hairpin structure to form a second two-dimensional hairpin structure. It can be moved by a press unit (not shown).

The first press unit (not shown) may press the two-dimensional hairpin structure moved by the first robot arm (not shown) to form a three-dimensional hairpin structure including the R-bending unit. The first press unit (not shown) may include a plurality of pairs of upper and lower frames corresponding to a plurality of R bending shapes, respectively. In this case, the control unit may rotate the first press unit (not shown) so as to use one of the plurality of pairs of upper and lower molds. Thereafter, a three-dimensional hairpin structure may be formed by pressing the two-dimensional hairpin structure using a first press unit (not shown). Similarly, the second press unit (not shown) may press the two-dimensional hairpin structure moved by the second robot arm (not shown) to form a three-dimensional hairpin structure including the R bending unit.

In one embodiment, the third robot arm (not shown) moves the three-dimensional hairpin structure formed by the first press unit (not shown) from the first press unit (not shown) to the first alignment device (not shown). It can be configured to For example, the third robot arm (not shown) may also include tongs for gripping the three-dimensional hairpin structure. Similarly, the fourth robot arm (not shown) may be configured to move the three-dimensional hairpin structure formed by the second press unit (not shown) from the second press unit (not shown) to the second alignment device (not shown). can

The above-described configuration of the first molding unit 320 may be equally applied to the second molding unit 420 . By forming the two-dimensional hairpin structure in the bending apparatus and the three-dimensional hairpin structure in the press unit, the time required to produce the hairpin can be reduced. In addition, by using two forming apparatuses (ie, two metal wire supply units, two forming units, and two pressing units), it is possible to shorten the time required to produce the hairpin. In addition, since the first press unit and the second press unit include a plurality of pairs of upper and lower molds, it is possible to quickly form hairpin structures of various shapes.

5 is a view showing an example in which the metal wire cut by the distributor 220 according to an embodiment of the present disclosure is provided to the first forming part 320 or the second forming part 420 . According to an embodiment, the distributor 220 may include at least one rail 530 and two grippers 542 and 544 on both sides. The at least one rail 530 may be configured to guide movement of the distributor 220 between the first position and the second position along a second axis (y axis) orthogonal to the first axis (x axis). Here, the first position refers to the position of the distributor 220 moved to the right along the second axis to supply the metal wire W cut by the distributor 220 to the second forming part 420 , and the second position The position may refer to the position of the distributor 220 moved to the left along the second axis in order to supply the metal wire rod (W) cut by the distributor 220 to the first forming part 320 .

According to an exemplary embodiment, the at least one rail 530 may include the metal wire W cut by the distributor 220 moving in the second axial direction to the first metal wire supply unit 310 or the second metal wire supply unit 410 . ), it may be disposed between the first metal wire supply unit 310 and the second metal wire supply unit 410 , as shown to selectively transmit. A moving member (not shown) configured to move in the second axial direction along the rail 530 may be disposed on the lower surface of the distributor 220 . Here, the moving member may be coupled to the rail 530 to move in the second axial direction to supply the cut metal wire W to the first metal wire supply unit 310 or the second metal wire supply unit 410 . . According to an embodiment, the distributor 220 may include a driving unit (not shown) configured to move the distributor 220 in the y-axis direction along the rail 530 . The controller controls the operation of the driving unit (not shown) so that the distributor 220 moves in the second axial direction to deliver the cut metal wire W to the first metal wire supply unit 310 or the second metal wire supply unit 410 . can be controlled

The first operation step 510 represents a state in which the distributor 220 provides the cut metal wire W to the second metal wire supply unit 410 . As shown, when the distributor 220 is located in the first position, the metal wire W cut by the cutting unit 210 before (eg, the second operation step 520 ) is cut into the second metal wire. It may be delivered to the supply unit 410 . For example, when the distributor 220 is located in the first position, the cut metal wire held by the right gripper 544 of the distributor 220 may be transferred to the second metal wire supply 410 . Additionally, when the distributor 220 is positioned in the first position, the left gripping part 542 of the distributor 220 may grip the metal wire W newly cut by the cutting part 210 . In this case, the controller may control the left gripping part 542 to grip a portion of the metal wire W before the cutting part 210 cuts the metal wire W. According to an embodiment, there may be a plurality of gripping units 542 and 544 , and as illustrated, they may be formed on both sides of the dispenser 220 .

The second operation step 520 represents a state in which the distributor 220 provides the cut metal wire W to the first metal wire supply unit 310 . As shown, when the distributor 220 is located in the second position, the metal wire W cut by the cutting unit 210 before (eg, the first operation step 510) is cut into the first metal wire. It may be transmitted to the supply unit 310 . For example, when the distributor 220 is positioned at the second position, the cut metal wire held by the left gripper 544 of the distributor 220 may be transferred to the first metal wire supply 310 . Additionally, when the distributor 220 is positioned at the second position, the right gripping part 544 of the distributor 220 may grip the metal wire W newly cut by the cutting part 210 . In this case, the controller may control the right gripping part 544 to grip a portion of the metal wire W before the cutting part 210 cuts the metal wire W.

While gripping the metal wire W through the distributor 220, the cut metal wire W is provided to the metal wire supply units 310 and 410, and the cut metal wire W is supplied to the first metal wire supply unit ( 310) and the second metal wire supply unit 410, by alternately supplying it, the time for the forming units 320 and 420 to generate the two-dimensional hairpin structure, the time for cutting the metal wire, and the time for moving the cut metal wire to the forming unit It is possible to minimize the time required for manufacturing the hairpin by minimizing the waiting time between the times. In addition, since the cut part cuts the metal wire in a state in which the grippers 542 and 544 of the distributor 220 hold a portion of the metal wire, it is possible to prevent the cut metal wire from falling off.

6 is a perspective view of a first molding part according to an embodiment of the present disclosure; According to an embodiment, the first molding unit may include a first stage 610 , a second stage 620 , a third stage 630 , and a fourth stage 640 . As illustrated, a first bending device 430 may be disposed on the upper surface of the first stage 610 . The second stage 620 may be configured to support the first stage 610 and guide movement of the first stage 610 in the z-axis direction. According to an embodiment, the second stage 620 may include a first guide rail 624 configured to guide the movement of the first stage 610 in the z-axis direction. For example, the first guide rails 624 may be disposed on both sides of the first stage 610 . The first molding unit may include a z-axis driving unit (not shown) configured to move the first stage 610 in the z-axis direction.

According to an embodiment, the first stage 610 may include a first moving member 612 configured to move in the z-axis direction along the first guide rail 624 of the second stage 620 . The first moving member 612 may be disposed on both sides of the first stage 610 . As shown, the first stage 610 moves in the z-axis direction by a z-axis driver (not shown) in a state in which the first stage 610 is supported by the second stage 620 . The member 612 may be coupled to the first guide rail 624 of the second stage 620 . Here, the z-axis driving unit may be configured to move the first stage 610 in the z-axis direction in order to move the first bending device 430 in the z-axis direction.

The controller controls a z-axis driving unit (not shown) to move the first stage 610 in the z-axis direction to move the first moving member 612 of the first stage 610 to the first of the second stage 620 . It can be moved along the guide rail 624 in the z-axis direction. The z-axis driver (not shown) may move the first moving member 612 in the z-axis direction based on a control signal from the controller to move the first stage 610 in the z-axis direction. Accordingly, the first bending device 430 disposed on the upper surface of the first stage 610 to bend the metal wire supplied from the first metal wire supply unit may move in the z-axis direction.

The third stage 630 may be configured to support the second stage 620 and guide movement of the second stage 620 in the y-axis direction. According to an embodiment, the third stage 630 may include a second guide rail 634 configured to guide the movement of the second stage 620 in the y-axis direction. The second guide rail 634 may be disposed on both sides of the third stage 630 . The first molding unit may include a y-axis driving unit (not shown) configured to move the second stage 620 along the y-axis direction.

According to an embodiment, the second stage 620 may include a second moving member 622 configured to move in the y-axis direction along the second guide rail 634 of the third stage 630 . The second moving member 612 may be disposed on both sides of the second stage 620 . As shown, the second stage 620 moves in the y-axis direction by a y-axis driver (not shown) in a state in which the second stage 620 is supported by the third stage 630 . The moving member 622 may be coupled to the second guide rail 634 of the third stage 630 . Here, the y-axis driver (not shown) moves the second stage 620 in the y-axis direction to move the first bending device 430 disposed on the upper surface of the first stage 610 in the y-axis direction. can be configured.

The controller controls the y-axis driving unit (not shown) to move the second stage 620 in the y-axis direction to move the second moving member 622 of the second stage 620 to the second of the third stage 630 . It can be moved along the guide rail 634 in the y-axis direction. The y-axis driving unit (not shown) may move the second moving member 622 in the y-axis direction to move the second stage 620 in the y-axis direction. Accordingly, the first stage 610 coupled to the second stage 620 is also moved in the y-axis direction so that the first bending device 430 disposed on the upper surface of the first stage 610 moves in the y-axis direction. can

According to an embodiment, the first forming unit moves the first bending device 430 in the x-axis direction with an x-axis driving unit (not shown) configured to move the first bending device 430 around a rotational center axis parallel to the z-axis. It may further include a rotation driving unit (not shown) configured to rotate. The fourth stage 640 may be configured to support the third stage 630 and guide movement in the x-axis direction. According to an embodiment, the fourth stage 640 may include a third guide rail 644 configured to guide the movement of the third stage 630 in the x-axis direction. For example, the third guide rails 644 may be disposed on both sides of the fourth stage 640 .

The third stage 630 may be configured to move along the x-axis direction by an x-axis driver (not shown). According to an embodiment, the third stage 630 may include a third moving member 632 configured to move along the third guide rail 644 of the fourth stage 640 in the x-axis direction. For example, the third moving member 632 may be disposed on both sides of the third stage 630 . In a state in which the third stage 630 is supported by the fourth stage 640 , an x-axis driver (not shown) may be configured to move the third stage 630 in the x-axis direction.

The controller controls the x-axis driving unit (not shown) to move the third stage 630 in the x-axis direction to move the third moving member 632 of the third stage 630 to the third of the fourth stage 640 . It can be moved along the guide rail 644 in the x-axis direction. The x-axis driving unit (not shown) may move the third moving member 632 in the x-axis direction to move the third stage 630 in the x-axis direction. Accordingly, the second stage 620 coupled to the third stage 630 and the first stage 610 coupled to the second stage 620 are also moved in the x-axis direction to form an upper surface of the first stage 610 . The first bending device 430 disposed in the can move in the x-axis direction.

By moving the first stage in the z-axis direction using the first guide rail and the first moving member, the first bending device may be moved in the z-axis direction. In addition, by moving the second stage and the first stage supported by the second stage in the y-axis direction using the second guide rail and the second moving member, the first bending device may be moved in the y-axis direction. Through this configuration, the structure and driving algorithm of the hairpin manufacturing apparatus can be further simplified, and the time required for manufacturing the hairpin by bending the metal wire can be minimized. Additionally, the third stage and the second stage and the first stage supported by the third stage may be moved in the x-axis direction by using the third guide rail and the third moving member.

The rotation driving unit (not shown) may be configured to rotate the first bending device about a rotation center axis (parallel to the z axis). According to an embodiment, the first bending member may be disposed on a rotational central axis. In addition, the second bending member may be disposed outside the central axis of rotation. In this case, the rotation driving unit (not shown) may be configured to rotate the first bending device about the rotation center axis of the second bending member. The control unit may bend the metal wire using one of the first bending member and the second bending member using the rotation driving unit.

The above-described configuration of the first molding unit may be equally applied to the second molding unit. According to an embodiment, the second molding unit includes a fifth stage configured to move along the z-axis direction by a z-axis driving unit, a sixth stage configured to support the fifth stage and guide movement in the z-axis direction, and a sixth stage. a seventh stage configured to support and guide movement in the y-axis direction, an eighth stage configured to support the seventh stage and guide movement in the x-axis direction, a y-axis drive configured to move the second bending device in the y-axis direction; a z-axis driving unit configured to move the second bending device in the z-axis direction, an x-axis driving unit configured to move the second bending device in the x-axis direction, and rotate the second bending device about a rotational center axis parallel to the z-axis It may include a configured rotation drive.

7 is a view illustrating an example of bending the metal wire W using the first bending member 432 according to an embodiment of the present disclosure. An example of a process of bending the metal wire W will be described based on the main configuration of the first bending device included in the first forming part. In one embodiment, the first bending device is moved in the y-axis direction by the y-axis driving part to form a two-dimensional hairpin structure in which the first U bending part, the V bending part, and the second U bending part are sequentially formed. The metal wire W supplied from the metal wire supply unit 310 may be bent by pressing the first bending member 432 .

The first operation step 710 represents a state immediately before the first bending member 432 bends the metal wire W. Referring to FIG. Before bending the metal wire W, the controller may control at least one of the z-axis driver and the y-axis driver to position the first bending device on the side of the metal wire W. For example, before performing bending of the metal wire W, the controller may control the z-axis driving unit to move the first bending member 432 of the first bending device to a height that can contact the metal wire W. can

In one embodiment, in order to adjust the length L of the bent metal wire W, the controller may control the first metal wire supply unit 310 to further supply the metal wire W cut in the x-axis direction. have. In another embodiment, the controller may move the first bending member 432 in the x-axis direction to adjust the length L of the bent metal wire W. After the first bending member 432 is disposed on the side of the metal wire W, the controller controls the y-axis driving unit so that the first bending member 432 applies a force to the metal wire W in the y-axis direction. can The second operation step 720 represents a state in which the first bending device moves in the y-axis direction to press the metal wire W with the first bending member 432 to form the first U-bending part. In a similar manner, the first bending device may move in the y-axis direction to press the metal wire W with the first bending member 432 to form the v-bending part and the second U-bending part.

In the above, the first bending member 432 of the first bending device moves in the y-axis direction in a state located on the side of the metal wire W to press the metal wire cut by the first bending member 432 to form a U bending part and forming the V-bending portion, but is not limited thereto. For example, the first bending device is positioned under the metal wire W by the operation of the z-axis driving part and/or the y-axis driving part, and the second bending member (not shown) is moved in the z-axis direction by the z-axis driving part. By moving to and bending the metal wire W by applying a force to the metal wire W, it is possible to form a U-bending part and a V-bending part.

7 illustrates an example of forming the first U-bending part, but is not limited thereto. For example, the controller controls the operation of the y-axis driver to move the first bending device in the y-axis direction to bend the metal wire and/or controls the operation of the z-axis driver to move the first bending device in the z-axis direction. The first U-bending part, the V-bending part, and the second U-bending part, etc. having a two-dimensional hairpin structure may be formed by moving the metal wire into By selectively using the method of bending the metal wire by moving the first bending device in the y-axis direction and the method of bending the metal wire by moving the first bending device in the z-axis direction, metal wires of various sizes and thicknesses (W ) can be bent to a desired shape/angle.

The above-described process of bending the cut metal wire W supplied from the first metal wire supply unit 310 by the first bending device is a process in which the second bending device bends the cut metal wire supplied from the second metal wire supply part. The same can be applied to the process.

8 is a perspective view of a two-dimensional hairpin structure 810 formed according to an embodiment of the present disclosure. The two-dimensional hairpin structure 810 includes a first U-bending part 820 , a V-bending part 830 , and a second U-bending part 840 formed by sequentially bending a metal wire by a first bending device or a second bending device. ) may be included. Here, the first U-bending part 820 , the V-bending part 830 , and the second U-bending part 840 may have different shapes depending on the type of electric motor to be produced. For example, the first U-bending part 820 , the V-bending part 830 , and the second U-bending part 840 may be bent to form an obtuse angle as illustrated. Also, the inner angle of the V-bending part 830 may be formed to be larger than the inner angles of the first U-bending part 820 and the second U-bending part 840 . As shown, the two-dimensional hairpin structure 810 is a flat structure in the z-axis.

As described above, the distance from each of the first U bending part 820 and the second U bending part 840 to the end of the metal wire cut by the cutting part, that is, the length of the leg of the two-dimensional hairpin structure 810 is It may be controlled by the metal wire supply unit (ie, the first metal wire supply unit or the second metal wire supply unit). The length of the leg may also have a different length depending on the type of electric motor to be produced. Each leg may be parallel on the xy plane. Accordingly, the metal wire formed by the first forming part or the second forming part may have a two-dimensional hairpin structure 810 .

9 is a top view of the first press unit 910 according to an embodiment of the present disclosure. The first press unit 910 may be configured to press the two-dimensional hairpin structure formed by the first molding unit in the z-axis direction to form a three-dimensional hairpin structure. As shown, the first press unit 910 includes a z-axis driving unit (not shown) and a first press unit (not shown) configured to move at least one of the plurality of upper and lower frame pairs 920 in the z axis direction ( It may include a rotation driving unit (not shown) configured to rotate 910 about a central axis of rotation parallel to the z axis. For example, the rotational central axis may be located at the center of the first press unit 910 . The control unit includes a z-axis driving unit (not shown) and a rotation driving unit such that one of a plurality of pairs of upper and lower frames of the first press unit 910 presses the two-dimensional hairpin structure in the z-axis direction to form a three-dimensional hairpin structure. (not shown) can be controlled.

The upper frame/lower frame pair 920 may be disposed to face each other in the z-axis direction. In this case, the upper frame/lower frame pair 920 may be configured to press the two-dimensional hairpin structure to form a three-dimensional hairpin structure including an R bending part. Here, the R bending part may have a different shape depending on the type of the electric motor to be produced. Each of the plurality of upper/lower frame pairs may be configured to form different shaped R bends. According to an embodiment, the plurality of pairs of upper and lower frames 920 may be rotated about a central axis of rotation by a rotation driving unit (not shown). As shown, the eight upper frame/lower frame pairs 920 may be arranged axially symmetrically with respect to the central axis of rotation.

The control unit controls a rotation driving unit (not shown) to form a three-dimensional hairpin structure suitable for the type of electric motor to be produced to rotate the plurality of upper frame/lower frame pairs 920 about the central axis of rotation to form one upper frame. You can choose between frame/subframe pairs. Thereafter, the control unit may control the first robot arm 930 to place the two-dimensional hairpin structure molded by the first forming unit in the selected upper frame/lower frame pair.

The first press unit 910 may further include a pressing unit (not shown) configured to press at least one of the selected upper frame and lower frame in the z-axis direction. According to an embodiment, the controller may control the z-axis driving unit (not shown) to move the upper frame in the z-axis direction. For this reason, the upper frame is pressed by the pressing unit and moved in the z-axis direction to press the two-dimensional hairpin. Here, the upper frame is an upper frame paired with a lower frame on which a two-dimensional hairpin structure is disposed, and the selected pair of upper frame/lower frame is pressed by a pressing unit in the z-axis direction by a rotation driving unit (not shown). It may be rotated and located below the pressing part.

Alternatively or additionally, the z-axis driver (not shown) may move the lower frame in which the two-dimensional hairpin structure is disposed in the z-axis direction based on a control signal from the controller. The upper frame and/or the lower frame may be moved in the z-axis direction by the z-axis driving unit to press the two-dimensional hairpin structure disposed on the lower frame. The two-dimensional hairpin structure may be formed into a three-dimensional hairpin structure including an R bending part by being pressed in the z-axis direction by at least one of an upper frame and a lower frame. When the two-dimensional hairpin structure is pressed by the first press unit 910 to form the three-dimensional hairpin structure, the second robot arm (not shown) grips a portion of the three-dimensional hairpin structure based on a control signal from the controller. to move from the first press unit 910 to the first alignment device.

The above-described configuration of the first press unit 910 may be equally applied to the second press unit. In one embodiment, the second press unit is a z-axis driving unit configured to move at least one of a plurality of pairs of upper and lower frames, and a plurality of pairs of upper and lower frames in the z-axis direction, and the second press unit is configured to move in the z-axis direction. It may include a rotation driving unit configured to rotate about a central axis of rotation parallel to and a pressing unit (not shown) configured to press at least one of the selected upper frame or lower frame in the z-axis direction.

10 is a perspective view of a pair of upper and lower frames 1040 according to an embodiment of the present disclosure. The pair of upper and lower frames 1040 may be configured such that at least one of the upper frame 1050 or the lower frame 1060 is movable in the z-axis direction by a z-axis driving unit (not shown). In one embodiment, each of the pair of upper and lower frames 1040 may be configured to be detachable from the first press unit or the second press unit.

The upper mold 1050 may include a protrusion 1052 for pressing the two-dimensional hairpin structure molded by the shaping part (ie, the first shaping part or the second shaping part). The lower mold 1060 may include a recess 1062 for pressing the two-dimensional hairpin structure at a position corresponding to the protrusion 1052 of the upper mold 1050 . Here, the lower frame 1060 may be disposed to face the upper frame 1050 , and the protrusion 1052 and the concave portion 1062 may have complementary shapes.

When the two-dimensional hairpin structure molded by the forming part is disposed in the recess 1062 of the lower frame 1060 by a first robot arm (not shown), at least one of the upper frame 1050 or the lower frame 1060 . may be moved in the z-axis direction by a z-axis driver (not shown) operated based on a control signal from the controller. For example, the upper frame 1050 and the lower frame 1060 may move in a direction closer to each other by a z-axis driving unit (not shown). Due to this, the protrusion 1052 of the upper frame 1050 and the concave portion 1062 of the lower frame 1060 press the two-dimensional hairpin structure in the z-axis direction to form a three-dimensional hairpin structure including the R bending part. have.

11 is a top view of the first press unit 1110 according to another embodiment of the present disclosure. In one embodiment, the first press unit 1110 includes a pressing unit (not shown) configured to press at least one of a pair of a first set of upper and lower frames, a first upper frame or a first lower frame, and x A shaft driving unit (not shown) may be included. Here, the pair of the upper frame and the lower frame of the first set may be arranged in a line. For example, the pair of upper and lower frames of the first set may be formed of a pair of eight upper and lower frames 1120 disposed opposite to each other in the z-axis direction, and as shown, the x-axis They may be arranged in a line along the direction. In one embodiment, each of the upper frame and the lower frame of the first set may be configured to be detachable from the first press unit 1110 .

According to an embodiment, the z-axis driving unit presses one of the pairs 1120 of the first set of upper and lower frames arranged in a line by using the pressing unit, the first set of the pair of upper and lower frames It may be configured to move 1120 in the x-axis direction. The control unit controls the z-axis driving unit to form a three-dimensional hairpin structure suitable for the electric motor to be produced to move the pair 1120 of the first set of upper and lower frames in the x-axis direction to form one upper frame and one lower frame. You can choose a pair of frames.

The pair of upper and lower frames of the first set may be moved in the x-axis direction by the third driving unit so that a selected pair of upper and lower frames may be located under the pressing unit. The controller may control the first robot arm 1130 to place the two-dimensional hairpin structure in the selected upper frame/lower frame pair.

Alternatively or additionally, the x-axis drive may be configured to move the press to press the two-dimensional hairpin structure using one of a pair 1120 of a first set of upper and lower frames arranged in line. have. The control unit may control the x-axis driving unit to move the pressing unit along the x-axis direction to form a three-dimensional hairpin structure suitable for the type of electric motor to be produced, thereby selecting one upper frame/lower frame pair. Thereafter, the controller may control the first robot arm 1130 to place the two-dimensional hairpin structure within the selected upper frame/lower frame pair.

The first press unit 1110 may further include a z-axis driving unit (not shown) configured to move at least one of the first upper frame and the first lower frame. According to an embodiment, the controller may control the z-axis driving unit to move the upper frame in the z-axis direction. For this reason, the upper frame is pressed by the pressing unit and moved in the z-axis direction to press the two-dimensional hairpin. Here, the upper frame is an upper frame paired with a lower frame on which a two-dimensional hairpin structure is disposed, and the selected pair of upper frame/lower frame is pressed in the z-axis direction by the pressing unit in the x-axis direction by the x-axis driver. It can be moved to the lower part of the pressing part.

Alternatively or additionally, the z-axis driver may move the lower frame in which the two-dimensional hairpin structure is disposed in the z-axis direction based on a control signal from the controller. The upper frame and/or the lower frame may be moved in the z-axis direction by the z-axis driving unit to press the two-dimensional hairpin structure disposed on the lower frame. When the two-dimensional hairpin structure is pressed in the z-axis direction by at least one of the upper frame and the lower frame to form the three-dimensional hairpin structure including the R bending part, the second robot arm (not shown) is based on the control signal from the control unit. Thus, a portion of the three-dimensional hairpin structure may be gripped and moved to the first alignment device.

The configuration of the above-described first press unit 1110 may be equally applied to the second press unit. In one embodiment, the second press portion is configured to move at least one of the first set of upper and lower mold pairs, the pressing portion configured to press at least one of the upper mold or the lower mold, the upper mold or the lower mold an x-axis drive configured to move the pair of upper and lower frames of the first set to press one of the pairs of upper and lower frames of the first set arranged in line using the shaft drive and press can Alternatively or additionally, the x-axis drive may be configured to move the press to press the second two-dimensional hairpin structure using one of the pair of upper and lower frames of the first set arranged in line. The pair of upper and lower frames of the first set may be arranged in a row along the x-axis direction, and the pair of upper and lower frames of the first set are, for example, 8 arranged opposite to each other in the z-axis direction. It may be formed as a pair of upper and lower frames. In addition, each of the upper frame and the lower frame of the first set may be configured to be detachable from the second press unit.

In FIG. 11 , the pair of the upper and lower frames of the first set and the pair of the upper and lower frames of the second set are each composed of eight pairs of upper and lower frames, but it is not limited thereto, and any number of pairs of upper and lower frames is not limited thereto. It may consist of a pair of an upper frame and a lower frame.

12 is a perspective view illustrating a two-dimensional hairpin structure 810 and a three-dimensional hairpin structure 1230 formed according to an embodiment of the present disclosure. As described above, the two-dimensional hairpin structure 810 may be pressed in the z-axis direction by the first press unit or the second press unit. Accordingly, the R-bending part 1240 may be formed in the flat two-dimensional hairpin structure 810 to be formed into the three-dimensional hairpin structure 1230 . As shown, the two-dimensional hairpin structure 810 has only two-dimensional curvature (a first U-bending portion, a V-bending portion, and a second U-bending portion) on a plane, whereas the three-dimensional hairpin structure 1230 has an R-bending portion. The portion 1240 may also have a curvature in three dimensions.

The hairpin manufacturing apparatus may include a control unit for controlling the operation of each component. The control unit may control the feeding device to cut the metal wire supplied along the first axis for each predetermined length. The controller may alternately supply the metal wire cut by the feeding device to the first forming device and the second forming device. The controller may control the first molding apparatus and the second molding apparatus to respectively bend and press the supplied cut metal wire to form a three-dimensional hairpin structure. In addition, the controller may control one or two robot arms to provide the three-dimensional hairpin structure molded by the first molding device and the second molding device to the first alignment device and the second alignment device, respectively.

Hereinafter, a process in which the controller controls the operation of the first forming apparatus to manufacture a hairpin using the cut metal wire will be described based on the main configuration of the first forming apparatus. When the first metal wire supply unit receives the cut metal wire from the distributor of the feeding device, the controller may control the first metal wire supply unit so that the first metal wire supply unit supplies the metal wire along the x-axis. When the first metal wire supply unit supplies the metal wire to the first forming unit along the x-axis, the control unit bends the cut metal wire supplied from the first metal wire supply unit by the first bending device to the first U bending unit and the V bending unit and the driving unit(s) may be controlled to form a two-dimensional hairpin structure in which the second U bending units are sequentially formed.

When the first bending device bends the metal wire to form a two-dimensional hairpin structure, the controller may control the robot arm to grip a portion of the two-dimensional hairpin structure in which the robot arm is formed. When the robot arm grips the two-dimensional hairpin structure, the control unit may control the robot arm to move the two-dimensional hairpin structure formed by the first forming part to the first press part and place it in the recess of the lower frame. Before the robot arm moves the two-dimensional hairpin structure molded by the first forming unit to the first press unit, the controller controls the first to which the two-dimensional hairpin structure is to be moved to form a three-dimensional hairpin structure suitable for the electric motor to be produced. The rotation driving unit may be controlled to rotate the press unit about the central axis of rotation to select one of a plurality of pairs of upper and lower frames. After the two-dimensional hairpin structure is disposed on the lower frame of the pair of upper and lower frames selected by the robot arm, the control unit presses the two-dimensional hairpin structure into the protrusion of the upper frame and the concave portion of the lower frame, so that the R bending part is included. The z-axis driver can be controlled to form a dimensional hairpin structure. When the three-dimensional hairpin structure is formed by the first press unit, the controller may control the robot arm to move the formed three-dimensional hairpin structure from the first press unit to the first alignment device.

The process in which the above-described controller controls the operation of the first forming apparatus to manufacture a hairpin through the cut metal wire may be equally applied to the second forming apparatus.

The above-described preferred embodiments of the present invention have been disclosed for the purpose of illustration, and various modifications, changes and additions will be possible within the spirit and scope of the present invention by those skilled in the art with respect to the present invention, and such modifications, changes and additions should be considered to be within the scope of the above claims.

Those of ordinary skill in the art to which the present invention pertains, within the scope of not departing from the technical spirit of the present invention, various substitutions, modifications and changes are possible, so the present invention is described in the above-described embodiments and the accompanying drawings. not limited by

110: decal device
120: peeling device
130: feeding device
140: first molding device
150: second molding device
160: first alignment device
170: second alignment device

Claims (10)

An apparatus for manufacturing a hairpin for an electric motor, comprising:
a cutting unit configured to cut the metal wire supplied along the first axis for every predetermined length;
a distributor configured to alternately supply the cut metal wire to the first forming apparatus and the second forming apparatus;
a first forming apparatus configured to form a first three-dimensional hairpin structure using the cut metal wire supplied from the distributor;
a second forming device configured to form a second three-dimensional hairpin structure using the cut metal wire supplied from the distributor;
at least one rail guiding the distributor to move between a first position and a second position along a second axis orthogonal to the first axis; and
a control unit configured to control operations of the cutting unit, the dispenser, the first forming device and the second forming device
including,
The control unit is
controlling the distributor so that when the distributor is in the first position, the cut metal wire is provided to the second forming apparatus,
and controlling the distributor so that the cut metal wire is provided to the first forming apparatus when the distributor is in the second position.
delete According to claim 1,
The first molding device,
a first metal wire supply unit configured to transfer the cut metal wire supplied from the distributor to the first forming unit along the first axis;
a first forming part configured to bend the cut metal wire supplied from the first metal wire supply part to form a first two-dimensional hairpin structure; and
a first press unit configured to press the first two-dimensional hairpin structure molded by the first forming unit to form a first three-dimensional hairpin structure
including,
The second molding device,
a second metal wire supply unit configured to transmit the cut metal wire supplied from the distributor to a second forming unit along the first axis;
a second forming unit configured to bend the cut metal wire supplied from the second metal wire supply unit to form a second two-dimensional hairpin structure; and
a second press unit configured to press the second two-dimensional hairpin structure molded by the second forming unit to form a second three-dimensional hairpin structure
Including, hairpin manufacturing apparatus.
4. The method of claim 3,
a first robot arm configured to move the first two-dimensional hairpin structure formed by the first forming part to the first pressing part; and
a second robot arm configured to move the second two-dimensional hairpin structure formed by the second forming part to the second pressing part
Further comprising, a hairpin manufacturing apparatus.
5. The method of claim 4,
The control unit is
The first forming part is controlled to bend the cut metal wire supplied from the first metal wire supply part to form a first two-dimensional hairpin structure in which a first U-bending part, a V-bending part, and a second U-bending part are sequentially formed,
controlling the first robot arm to move the first two-dimensional hairpin structure to the first press unit;
controlling the first press unit to press the first two-dimensional hairpin structure to form a first three-dimensional hairpin structure including an R bending unit;
The second forming part is controlled to bend the cut metal wire supplied from the second metal wire supply part to form a second two-dimensional hairpin structure in which the first U-bending part, the V-bending part, and the second U-bending part are sequentially formed,
controlling the second robot arm to move the second two-dimensional hairpin structure to the second press unit;
controlling the second press unit to press the second two-dimensional hairpin structure to form a second three-dimensional hairpin structure including an R bending unit;
Hairpin making device.
6. The method of claim 5,
The first molding part,
a first bending device including a first bending member and a second bending member;
a first driving unit configured to move the first bending device in a second axis direction orthogonal to the first axis;
a second driving unit configured to move the first bending device in a third axis direction orthogonal to the first axis and the second axis
including,
The second molding part,
a second bending device including a third bending member and a fourth bending member;
a third driving unit configured to move the second bending device in a second axis direction orthogonal to the first axis;
a fourth driving unit configured to move the second bending device in a third axis direction orthogonal to the first axis and the second axis
including,
and the first bending member, the second bending member, the third bending member and the fourth bending member extend along the third axis.
7. The method of claim 6,
The control unit is
To form the first two-dimensional hairpin structure in which the first U bending part, the V bending part, and the second U bending part are sequentially formed, the first driving part is controlled so that the first bending device moves in the second axial direction, or ,
In order to form the first two-dimensional hairpin structure in which the first U bending part, the V bending part, and the second U bending part are sequentially formed, the second driving part is controlled so that the first bending device moves in the third axial direction , a device for manufacturing hairpins.
7. The method of claim 6,
The first press unit,
a first upper frame including a first protrusion;
a first lower frame having a first concave portion and facing the first upper frame; and
a fifth driving unit configured to move at least one of the first upper frame and the first lower frame in the third axial direction
including,
The control unit is
controlling the first robot arm so that the first two-dimensional hairpin structure molded by the first forming part is disposed in a first concave part of the first lower frame,
and controlling the fifth driving unit to press the first two-dimensional hairpin structure with the first protrusion and the first concave portion to form a first three-dimensional hairpin structure including the R-bending portion.
9. The method of claim 8,
The first press unit,
a second upper frame including a second protrusion;
a second lower frame having a second concave portion and facing the second upper frame; and
Further comprising a sixth driving unit configured to rotate the first press unit about a central axis of rotation,
The central axis of rotation is parallel to the third axis,
The control unit controls the sixth driving unit to press the first two-dimensional hairpin structure by selecting one of the first upper frame and the first lower frame, or the second upper frame and the second lower frame. , a device for manufacturing hairpins.
10. The method of claim 9,
The first upper frame and the first lower frame face the second upper frame and the second lower frame with the central axis of rotation interposed therebetween.

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