KR20240110197A - Apparatus For Forming Hairpin Conductors - Google Patents

Abstract

An apparatus for forming a metal wire into the shape of a hairpin conductor is introduced. This device includes a wire feeder; A bending machine for bending and forming the wire from the wire supply device; A cutting machine that cuts the wire formed in the bending machine; and a press molding machine. The bending machine includes a bending block having a groove formed on the upper surface through which a wire flows in a radial direction; A vise configured to descend to restrain the wire and rise to release the restraint on the wire; and a bending tool configured to bend the wire at the exit side of the groove.

Description

Apparatus For Forming Hairpin Conductors}

The present invention relates to an apparatus for forming a metal wire into the shape of a hairpin conductor.

An electric motor or generator is provided with a stator and a rotor that moves relative to the stator. The stator typically consists of a slotted core and a winding wound around the slots. Recently, in order to reduce heat loss (Jule Loss), the adoption of hairpin windings, which were previously used in large motors for railway vehicles, has been expanding.

The efficiency of electric vehicle drive motors is directly related to electric vehicle performance. One of the ways to increase motor efficiency is to reduce copper loss reduction. Improving the space factor of windings is suggested as an effective method of reducing copper loss, and the demand for hairpin windings is continuously increasing to improve the space factor.

Figure 1 shows an example of a hairpin conductor 3 used in a hairpin winding.

Referring to FIG. 1, the hairpin conductor 3 is manufactured in a hairpin shape using a wire with a square cross-section. The hairpin conductor (3) has a head (4) and two legs (6a, 6b: 6). The head 4 includes first to third bending portions 5a, 5b, and 5c, and has a three-dimensional shape bent in the z direction.

The present invention seeks to provide a hairpin conductor forming device with a simple configuration.

Additionally, the present invention seeks to provide a hairpin conductor forming device with excellent mass production properties.

Additionally, the present invention seeks to provide a hairpin conductor forming device capable of in-line continuous production.

The problems to be solved by the present invention are not necessarily limited to the matters mentioned above, and other problems not yet mentioned may also be understood by the matters described below.

The above objectives are achieved by the inventions and configurations described in the claims. The hairpin conductor forming device according to the present invention includes a wire supply device; A bending machine for bending and forming the wire from the wire supply device; and a cutting machine that cuts the wire formed in the bending machine.

The bending machine of the hairpin conductor forming device according to the present invention is characterized by a bending block having a groove formed on the upper surface through which a wire flows in a radial direction, where the groove has an inlet and an outlet; A vise having a gripper vertically inserted into the groove and configured to descend to restrain the wire and rise to release the restraint on the wire; and a bending tool configured to bend the wire while rotating around the bending block at the exit side of the groove.

According to the present invention, the bending block can be lifted and rotated, and the curvature of the first edge and the second edge at the exit of the groove are different from each other. When the bending block rotates 180 degrees, the third edge of the groove entrance is placed at the second edge position, and the fourth edge of the groove entrance is placed at the first edge position. The curvature of the first edge and the third edge are the same, and the curvature of the second edge and the fourth edge are the same.

According to the present invention, the wire supply device includes an unwinder in which a wire is wound; Straightener to impart straightness to the wire from the unwinder; and a feeding machine for holding and moving the wire from the strater and feeding it to the bending machine. The feeding machine includes a guide rail; It is movable along the guide rail and has a fixed jaw and a movable jaw to firmly hold the wire.

Additionally, according to the present invention, the unwinder includes a slide rail disposed perpendicular to the wire supply direction; and an unwind roll that can move along the slide rail and unwinds the wire. The unwind roll is configured to move along the slide rail so that the current position of the wire pulley in the unwind roll is in line with the direction of wire travel in the straightener.

According to the present invention as described above, a hairpin conductor forming device can be simply constructed by applying existing technologies for a wire supply device, cutting machine, and press forming machine, or by partially modifying a commercially available product.

Additionally, according to the present invention, it is possible to easily manufacture hairpin conductors having bending parts with different curvatures using a simply constructed bending block and vise.

In addition, according to the present invention, in-line molding is possible while continuously transferring the wire, so mass production is excellent.

Additionally, according to the present invention, in-line continuous production of hairpin conductors is possible.

Figure 1 shows an example of a hairpin conductor.
Figure 2 shows a hairpin conductor forming device according to an embodiment of the present invention.
Figure 3 is an enlarged view of the unwinder shown in Figure 1.
Figure 4 is an enlarged view of the straightener and feeder shown in Figure 1.
Figure 5 is an enlarged view of the bender and cutter shown in Figure 1.
Figure 6 is an enlarged view of the press molding machine shown in Figure 1.
Figures 7a to 7g sequentially show the wire bending process.

Hereinafter, we will look at examples in more detail so that we can understand various characteristic aspects of the present invention. In the drawings, identical or equivalent components may be indicated by the same symbols, and the drawings may be exaggerated or schematically shown for intuitive understanding of the features of the present invention.

In this document, unless otherwise specified or inherently impermissible, expressions to describe the relationship between two elements, such as 'phase' and 'connection', refer to the two elements being in direct contact with each other. Of course, a third element is allowed to be inserted between the first and second elements. Directional indications such as front and back, left and right, or up and down are only for convenience of explanation.

Figure 2 shows a hairpin conductor forming apparatus according to an embodiment.

Referring to FIG. 2, the molding device includes a wire supply device (10, 20, 30), a bending machine (40), a cutting machine (50), and a press molding machine (60). The wire (1) is continuously supplied from the wire supply device (10, 20, 30) to the cutting machine (50), and is cut by the cutting machine (50) to obtain a hairpin semi-finished product (2). The hairpin conductor (3) is obtained by molding the hairpin semi-finished product (2) in the press molding machine (60). The hairpin conductor forming devices are arranged in a row on the frame (8).

The wire supply device (10, 20, 30), bending machine (40), cutting machine (50), and press forming machine (60) are examined sequentially along the direction in which the wire (1) travels. x represents the longitudinal direction in which the wire 1 travels, y represents the width direction, and z represents the height direction. Wire 1 runs in the +x direction from upstream to downstream. Upstream is also referred to as the rear, and downstream is also referred to as the front.

3 and 4 show wire feeders 10, 20, and 30. The feeding devices 10, 20, and 30 include an unwinder 10, a straightener 20, and a feeding machine 30. An unwinder 10 is shown in FIG. 3, and a straightener 20 and a feeder 30 are shown in FIG. 4.

2 and 3, the unwinder 10 includes a slide rail 15 and an unwind roll 11 that can move along the slide rail 15. The slide rail 15 is arranged in the y direction perpendicular to the x direction along which the wire travels. The wire 1 is wound around the unwind roll 11, and the wire 1 is supplied forward from the unwind roll 11 to form the wire 1.

The unwind roll (11) is installed on the base (12) using a bracket (13). A bracket 13 is fixed to the upper surface of the base 12, and a slider 14 that moves on the rail 15 is provided to the lower surface of the base 12. On one side of the rail 15, a driving device such as a belt 16, a ball screw 17, and a motor (not shown) is provided to reciprocate the base 12 on the rail 15. The unwind roll 11 has a shaft 180 for rotatably mounted on the bracket 13.

A guide 19 having slits 9 formed in the vertical direction is installed in front of the unwind roll 11. The guide 19 is placed in a straight line with the direction of movement (straightening direction) of the wire 1 in the straightener 20 and is fixed in position. The wire (1) unwinded from the unwind roll (11) passes through the slit (9) and is supplied to the front straightener (20). When the wire (1) is unwinded from the unwind roll (11), the base (12) moves so that the current position where the wire (1) is unwound from the unwind roll (11) is aligned with the guide (19). .

Referring to FIG. 4, the straightener 20 corrects the deformation of the wire 1 supplied from the unwinder 10 and provides straightness. The straightener 20 includes a first roller 21 for leveling in the left and right directions, a second roller 22 for leveling in the up and down directions, and a third roller 23 for leveling in the left and right directions. The straightener 20 may be constructed using various technologies or commercially available products.

The feeding machine 30 grabs the leveled wire 1 from the strata 20 and moves it forward to supply it to the bending machine 40. The feeding machine 30 includes a guide rail 35 disposed in the x-direction and a sliding body 31 movable along the rail 35. The sliding body 31 is provided with a fixed jaw 32 and a movable jaw 33 for firmly holding the wire 1. The feeding machine 30 includes a first motor 36 for moving the sliding body 31 and a second motor 34 for lifting and lowering the movable jaw 33.

When the feeding machine 30 moves forward while holding the wire 1, the wire 1 wound around the unwind roll 11 is unwound. The unwind roll 11 rotates due to the force with which the feeding machine 30 pulls the wire 1 forward, and the wire 1 wound around the unwind roll 11 is unwinded. The unwinder (10) is equipped with an appropriate auxiliary device to control the rotation of the unwind roll (11) so that the wire (1) can be properly unwound in response to the force with which the feeding machine (30) pulls the wire (1). can do.

FIG. 5 shows a bending machine 40 for bending and forming the wire 1.

Referring to Figures 1 and 5, the bending machine 40 is equipped with a guide roll 45, wire grip mechanisms 42 and 45, and a bending tool 43 for guiding the wire 1 from the straightener 20. do. In the bending machine 40, first to third bending parts 5a, 5b, and 5c are formed on the wire 1. According to the embodiment, the curvature radii of the first bending part 5a and the third bending part 5c are the same, and the curvature radius of the second bending part 5b is different from the other two bending parts 5a and 5c.

The guide roll 45 consists of horizontally arranged twin rolls. Wire (1) passes between the twin rolls. The guide roll 45 guides the wire 1 to proceed in a direction that can be accurately gripped by the grip mechanisms 42 and 45.

The wire grip mechanisms 42 and 45 have a lower bending block 42 and an upper vise 45.

The bending block 42 has a groove 47 through which the wire 1 flows from the guide roll 45. The groove 47 is formed on the upper surface of the bending block 42 in a radial direction, in other words, in the x-direction along which the wire 1 travels, and has an inlet on the side of the guide roll 45 and an outlet on the side opposite to the inlet. The wire 1 is introduced into the entrance of the groove 47, proceeds along the groove 47, and is supplied to the front through the outlet. The bending block 42 can be lifted and rotated, and the inlet and outlet of the groove 47 are changed each time it rotates 180 degrees.

The vise 45 is mounted to be lifted up and down within the housing 44 and is provided with a gripper 46 (see FIG. 7) to firmly grasp the wire 1. With the wire 1 placed in the groove 47 of the bending block 42, when the vise 45 descends, the wire 1 is restrained, and when the vise 45 rises, the restraint on the wire 1 is released. The gripper 46 is formed in a shape that can be inserted perpendicularly into the groove 47, and presses and restrains the wire 1 placed in the groove 47.

The bending tool 43 is configured to bend the wire 1 while rotating around the bending block 42 at the exit side of the groove 47. As shown in FIG. 5, the bending tool 43 rotates clockwise to bend the wire 1 exposed outside beyond the outlet. As an example, if the outlet of the groove 47 is located at 3 o'clock, the bending tool 43 before forming the wire 1 is placed at 2 o'clock or almost in a straight line with the direction in which the wire 1 travels. . The bending tool 43 rotates in the 4 o'clock direction while pushing the wire 1, and the wire 1 is bent.

FIG. 5 shows a cutter 50 for cutting the bent wire 1.

Referring to FIG. 5, the hairpin semi-finished product 2 is obtained by cutting the formed wire 1 in the bending machine 40. The cutting machine 50 is disposed in front of the bending machine 40, and the storage table 7 is disposed in front of the cutting machine 50. After bending and forming, the wire 1 is moved forward by the feeding machine 30, and the semi-finished hairpin product 2 cut by the cutting machine 50 falls on the storage table 7 and is temporarily stored.

The cutting machine 50 includes a lower cutting block 52 and a movable cutter 51. The cutter 50 is provided with a cylinder for lifting and lowering the movable cutter 51.

6 shows a press molding machine 60 for forming the head of the hairpin semi-finished product 2.

Referring to Figures 1 and 6, a three-dimensional shape bent in the z direction is given to the hairpin semi-finished product 2 in the press molding machine 60. The press molding machine 60 is equipped with an upper die 62, a lower die 61, and a servomotor 63 for lifting and lowering the upper die 62. For example, a transfer robot (not shown) or an operator transfers the hairpin semi-finished product 2 from the storage table 7 and loads it into the lower die 61, by joining the lower die 61 and the upper die 62. A hairpin conductor (3) is obtained.

7A to 7G, detailed components of the bending machine 40 and the forming process of the wire 1 using the bending machine 40 are sequentially shown. In FIG. 7E, the bending block 42 is in the lowered position, and in the remaining figures, the bending block 42 is in the raised position.

Referring to FIGS. 7A and 7B, the wire 1 supplied in the x direction by the feeding machine 30 passes through the guide roll 41 and is guided into the groove 47. The groove 47 is placed in a straight line with the direction of movement of the wire 1, and the wire 1 passes through the outlet of the groove 47 and is supplied up to a certain length forward. By way of example, the wire 1 is advanced forward from the outlet the length of the leg 6 of the hairpin conductor 3.

The curvatures of the first edge 47a and the second edge 47b facing each other at the exit of the groove 47 are different. The curvatures of the third and fourth edges 47c and 47d (see FIG. 7E) that face each other at the entrance of the groove 47 are also different. Referring to FIG. 7E, when viewed in the x-direction along which the wire 1 travels, the curvature of the first edge 47a and the third edge 47c located on the right side of the groove 47 are the same, and the groove 47 The curvature of the second edge (27b) and the fourth edge (47d) located on the left side of is the same.

The bending tool 43 has two upper rolls and a lower rotatable body. A groove 43a in which the wire 1 is accommodated is formed in the two rolls in the circumferential direction. The groove 43a is disposed at a height where the wire 1 is positioned so as to accommodate the wire 1 and/or stably provide a horizontal force in the rotational direction to the wire 1. When bending the wire (1), the wire (1) placed in the groove (43a) of the bending tool (43) is pushed and rotated clockwise.

Referring to Figure 7b, the vise 45 is lowered to firmly grip the wire 1. The vise 45 is lowered to a depth at which the gripper 46 enters the groove 47 in a vertical direction and restrains the wire 1. When the wire 1 is firmly restrained between the gripper 46 and the groove 47, as shown in FIG. 7C, the bending tool 43 rotates clockwise to form the first bending portion 5a.

Referring to FIGS. 7A and 7C , when the first bending portion 5a is formed, the wire 1 is formed with a curvature corresponding to the curvature of the first edge 47a. It is obvious that the curvature of the first bending portion 5a and the curvature of the first edge 47a may not be completely the same, and the curvature of the first edge 47a is the target curvature of the first bending portion 5a. It is designed to obtain.

Referring to FIGS. 7C and 7D, after forming the first bending portion 5a, the bending tool 43 rotates counterclockwise and returns to its original position, and the vise 45 rises to release the restraint on the wire 1. . Afterwards, as shown in FIG. 7D, the wire 1 is first advanced in the x-direction by the feeding machine 30. The length of the first advance corresponds to the length between the first bending portion 5a and the second bending portion 5b.

Referring to FIG. 7E, the bending block 42 is lowered and rotated 180 degrees to form the second bending portion 5b. As the bending block 42 descends, interference between the bending block 42 and the wire 1 is avoided. When the bending block 42 rotates 180 degrees, the fourth edge 47d of the inlet is placed at the position of the first edge 47a of the outlet of the groove 47, and the third edge of the inlet is placed at the position of the second edge 47b. (47c) is placed. Accordingly, when the second bending portion 5b is formed, the wire 1 is formed with a curvature corresponding to the curvature of the fourth edge 47d. The first edge 47a and the fourth edge 47d have different radii of curvature.

After the 180 degree rotation described above, the bending block 42 rises, thereby positioning the wire 1 within the groove 47 . Then, the vise 45 descends to restrain the wire 1 between the groove 47 and the gripper 46, and the bending tool 43 rotates clockwise to form a second bending portion 5b on the wire 1. is molded.

After forming the second bending portion 5b is completed, the bending tool 43 rotates counterclockwise and returns to its original position, and the vise 45 rises to release the restraint on the wire 1. Then, the wire 1 is advanced in the x-direction a second time by the feeding machine 30. The length of the secondary advance corresponds to the length between the second bending portion 5b and the third bending portion 5c. Since the forming process of the second bending part 5b is carried out in the same manner as the forming of the first bending part 5a, the drawings for this are not separately shown.

Figure 7f shows that the third bent portion 5c is formed on the wire 1.

Referring to FIG. 7F, after the second advancement of the wire 1, the bending block 42 descends and rotates 180 degrees to form the third bending portion 5c, and then rises again to its original position. By this 180-degree rotation, the first edge 47a and the second edge 47b are placed on the exit side of the groove 47. When the vise 45 is lowered and the wire 1 is restrained by the gripper 46, the bending tool 43 rotates clockwise to form a third bending portion 5c in the wire 1. When forming the third bending portion 5c, the wire 1 is formed with a curvature corresponding to the curvature of the first edge 47a. The first bending portion 5a and the third bending portion 5c have the same curvature radii. After forming the third bending portion 5c, the bending tool 43 returns to its original position and the vise 45 rises to release the restraint on the wire 1.

Figure 7g shows the process of cutting the wire 1 by the cutter 50.

Referring to FIG. 7g, after completion of forming the third bending portion 5c, the wire 1 is advanced three times in the x-direction by the feeding machine 30. The third advance corresponds to twice the length of the leg (6) of the hairpin conductor (3). Following the third advance, the movable cutter 51 of the cutting machine 50 operates to cut the wire 1, thereby obtaining the hairpin semi-finished product 2.

After cutting the wire 1, as shown in FIGS. 7A to 7G, forming of the first to third bending parts 5a, 5b, and 5c proceeds sequentially. Productivity is excellent because bending and cutting processes are performed while the wire 1 is continuously supplied.

Embodiments of the present invention have been described above, and these embodiments will be helpful in understanding various aspects and features of the present invention. The features or elements introduced in these embodiments may be combined in various forms, and such combinations may provide another embodiment that has not yet been described in this document.

The scope of the invention sought to be protected is set forth in the claims. The elements described in the claims may be variously changed, modified, and replaced with equivalents without departing from the essence or scope of the invention. The reference numerals in the claims, if provided, are only intended to facilitate easy and intuitive understanding of the claimed inventions or their elements and do not limit the scope of the claimed inventions.

1: Wire 2: Hairpin semi-finished product
3: hairpin conductor 10: unwinder
11: Unwind roll 14: Slider
15,35: Rail 20: Straightener
21,22,23: Roller 30: Feeding machine
40: bending machine 41: guide roll
42: bending block 43: bending tool
44: housing 45: vise
47: Groove 50: Cutting machine
60: press molding machine 61,62: die

Claims (4)

wire feeder (10, 20, 30);
A bending machine (40) for bending and forming the wire (1) from the wire supply device (10, 20, 30); and
It includes a cutter (50) for cutting the wire (1) formed in the bending machine (40),
The bending machine 40,
A bending block 42 having a groove 47 formed on the upper surface through which the wire 1 flows in the radial direction, and the groove 47 has an inlet and an outlet;
A vise (45) including a gripper (46) inserted perpendicularly into the groove (47) and configured to descend to restrain the wire (1) and rise to release the restraint on the wire (1); and
A hairpin conductor forming device including a bending tool (43) configured to bend the wire (1) while rotating around the bending block (42) at the exit side of the groove (47). The method according to claim 1, wherein the bending block (42) is capable of lifting and rotating,
At the exit of the groove 47, the curvatures of the first edge 47a and the second edge 47b are different from each other,
When the bending block 42 is rotated 180 degrees, the fourth edge 47d of the entrance of the groove 47 is placed at the position of the second edge 47b, and the entrance of the groove 47 is placed at the position of the first edge 47a. The third edge 47c is placed,
A hairpin conductor forming device in which the first edge (47a) and the third edge (47c) have the same curvature, and the second edge (47b) and the fourth edge (47d) have the same curvature. The method according to claim 1, wherein the wire supply device,
An unwinder (10) around which the wire (1) is wound;
a stratator (20) for imparting straightness to the wire (1) from the unwinder (10); and
It includes a feeding machine 30 for holding and moving the wire 1 from the strater 20 and supplying it to the bending machine 40. The feeding machine 30 includes,
guide rail (35); and
A hairpin conductor forming device comprising a sliding body (31) that is movable along the guide rail (35) and has a fixed jaw (32) and a movable jaw (33) for firmly holding the wire (1). The method of claim 3, wherein the unwinder (10),
a slide rail (15) disposed perpendicular to the supply direction of the wire (1); and
It is movable along the slide rail (15) and includes an unwind roll (11) on which the wire (1) is unwinded,
The unwind roll 11 moves the slide rail 15 so that the current position where the wire 1 is unwound from the unwind roll 11 is aligned with the direction of progress of the wire 1 in the straightener 20. A hairpin conductor forming device configured to move along.

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