TW201944707A - Device and method for manufacturing wire for wound stator of automotive generator and method - Google Patents

Abstract

The disclosure provides a device and a method for manufacturing a wire for a wound stator of an automotive generator. The wire includes a core and a coating surrounding the core. The wire manufacturing device includes a coating removing component, a movable holding component, a deforming component and a flattening component. The coating removing component is configured for removing the coating at a first position. The movable holding component is configured for holding and moving the wire from a first position to a second position. The deforming component is configured for deforming the wire into a waved shape. The flattening component is configured for flattening several parts of the wire that are spaced apart from each other.

Description

Device and method for manufacturing winding stator wire of vehicle generator

The present invention relates to a device and method for making a wire, and more particularly to a device and method for making a wire and a winding stator of a vehicle generator.

Alternating current generators are basically used to convert mechanical energy into electrical energy in the form of alternating current. When a vehicle is equipped with an alternator, an induced current can be generated through the combined operation of a stator and a rotor driven by an engine. In detail, the rotor includes a set of coils that surround the metal core, and the current passing through the coils generates a magnetic field that surrounds the metal core. The strength of the magnetic field is determined by the field strength of the exciting current. The field strength can be a DC current supplied by the brush and the slip ring. When an engine is running, the rotor is driven and rotated by an alternator pulley coupled to the engine.

A magnetic field is generated by a plurality of electric wires wound around a certain core. The stator core is a cylinder having a plurality of teeth and formed on an inner peripheral surface of the cylinder. The wire is wound in a groove between the teeth. It is well known that the strength of the magnetic field is determined by the density of the wires wound around the stator core and how the wires are wound in the grooves. If the wires are arranged in an irregular manner, the groove may have more air gap, which will cause electromagnetic impedance and reduce the power generation effect.

In a conventional method for manufacturing a stator of an AC generator, a straight wire is bent around a jig to form a wave shape, and then the wire is cut to have a predetermined length. Next, the worker inserts a wavy wire into a groove in the stator core. In order to manufacture such a stator, multiple workers are required to make it, which will cause high cost and low efficiency. Furthermore, since the wires need to be cut manually, the length of each cut wire may be inconsistent. Therefore, after the electric wire is wound around the stator core, another worker needs to trim the electric wire so that a plurality of electric wires have approximately the same length, and the section of the electric wire that is cut will cause waste. In other words, the conventional method is complicated, time-consuming, expensive, and may produce inconsistent production quality.

Therefore, an apparatus and method for manufacturing a winding stator and an electric wire for a vehicle generator, which can make the winding stator provide better manufacturing quality and high power generation efficiency, are expected by the industry.

According to an embodiment of the present disclosure, a device for manufacturing an electric wire for a winding stator of a vehicle generator is provided. The wire includes a core and a covering around one of the cores. The device includes a cover removing component, a mobile holding component, a deforming component, and a leveling component. The cover removal component is configured to remove the cover in a first position. The mobile holding component is configured to hold and move the wire from a first position to a second position. The deformation assembly is configured to deform the wire into a wave shape. The leveling assembly is configured to level parts of the electrical wire that are separated from each other.

According to another embodiment of the present disclosure, a method for manufacturing a winding stator and a wire of a vehicle generator is provided. The method is generally described as follows. Remove a covering of a first segment of a wire at a first location. The wire is moved from the first position to and held in a second position. A middle section of the electric wire is transformed into a wave shape, so that the electric wire forms a plurality of linear portions and a plurality of U-shaped portions that are staggered with each other. Remove the covering of the second section of one of the wires at the first position, and the middle section connects the first section and the second section. Cut the wire so that the first, middle, and second sections of the wire are separated from the rest of the wire. Transform the first and second sections into waves.

According to another embodiment of the present disclosure, a method for manufacturing a winding stator and a wire of a vehicle generator is provided. The method is generally described as follows. A wire is provided including a core and a covering around the core. The wire is defined to have a first wire unit and a second wire unit. The first wire unit has a first section, a second section, and a first section. An intermediate paragraph between the second and second paragraphs. Remove the cover of the first paragraph to expose the core of the first paragraph. Hold on to the first paragraph. The parts of the middle section that are separated from each other are pushed to deform the middle section to form a plurality of staggered straight sections and a plurality of U-shaped sections, thereby forming a wave shape. Remove the cover at one end of the second paragraph. Cut the wires to separate the first wire unit from the second wire unit. Push the first and second paragraphs to transform the first and second paragraphs into waves, respectively. Squeeze the straight part to flatten its cut surface.

In order to better understand the features, contents and advantages of this disclosure and the effects that can be achieved, the disclosure is described in detail in conjunction with the accompanying drawings and in the form of examples in the following, and the main purpose of the drawings is only For the purpose of illustrating and assisting the description, the relationship between the proportion and configuration of the attached drawings should not be interpreted, and the scope of patent application of this disclosure should not be limited.

The terms used in the description of this disclosure are only used to describe specific embodiments, and are not intended to limit the scope of patent application of this disclosure. In the description of the present invention and the scope of the attached patent application, the terms "a" or "the", unless explicitly stated otherwise, mean that the singular includes the plural. It is to be understood that the term "and / or" herein may include any or all combinations of the associated listed elements. It is further understood that the terms "including" and / or "including" in the description herein are used to clarify the existence of said multiple features, things, steps, operations, elements and / or components, but do not exclude one or at least one The presence or addition of features, things, steps, operations, elements, components and / or combinations thereof.

The disclosure provides a wire making system for shaping a coil of wire into a wave shape (ie, a meandering shape, a sine wave shape, or a sawtooth shape) and flattening a plurality of portions of the wire. This disclosure also provides a method of making such wires using a wire making system. The wires provided by the wire making system can then be wound around a core to form a winding stator for a vehicle generator. In one embodiment, the vehicle generator may be, but is not limited to, an AC generator. Vehicle generators can provide electrical energy to various electronic components mounted on vehicles, such as lamps, infrared sensors, air conditioners, radios, reversing cameras, and so on.

FIG. 1 is a top view of a wire manufacturing system 100 according to an embodiment of the disclosure. In one embodiment, the wire manufacturing system 100 includes a cover removal assembly 110, a mobile holding assembly 120, a deformation assembly 130, and a leveling assembly 140. In some embodiments, the wire manufacturing system 100 further includes a wire providing assembly 150 and a lifting assembly 160. The cover removing component 110 may be disposed between the wire providing component 150 and the deforming component 130, and the movable holding component 120 may be movably disposed above the deforming component 130. The leveling component 140 may be disposed adjacent to the deforming component 130, and the lifting component 160 may be disposed above the leveling component 140 and the deforming component 130. The structure of the wire manufacturing system 100 is not limited to the detailed embodiment described above and illustrated in FIG. 1. Those skilled in the art can obviously know that the wire making system 100 in other embodiments can have other structures and layouts without exceeding the spirit of the present disclosure.

FIG. 2 is an enlarged top view of a wire providing component 150, a cover removing component 110, and a mobile holding component 120 of the wire manufacturing system 100 of FIG. The wire providing assembly 150 may be configured to provide and deliver one of the wires 200 to be processed. The electric wire providing assembly 150 can straighten a coil of electric wires (not shown) to have a straight shape. In some embodiments, the electric wire 200 has a core and a cover. The core may be made of copper, and the cover surrounds the core. The cover is made of an insulating material to prevent the core from contacting other parts of the stator. For example, the insulating material may be polyurethane, polyurethane, polyamide, or polyesterimide. The wire providing assembly 150 may further include a first set of guide wheels 210 and a second set of guide wheels 220. The first set of guide wheels 210 is configured to straighten the electrical wires 200 vertically. The second set of guide wheels 220 is configured to further straighten the electric wire 200 horizontally. Therefore, the electric wire 200 is straightened and then smoothly transferred to the cover removal assembly 110.

The cover removal assembly 110 may be configured to remove (ie, strip) the cover of the electrical wire 200. In some embodiments, the cover removal assembly 110 may include a motor 230, a base 240 and a peeler 250. The motor 230 and the base 240 provide a channel 232 therein to receive the electric wire 200. The base 240 is connected to the motor 230, and the motor 230 is configured to drive the base 240 to rotate about an axis A1 (as shown by a dashed line in FIG. 2) aligned with the channel 232. The peeler 250 includes one or more arms 252 and one or more cutters 254. In one embodiment, the number of the arms 252 and the number of the cutters 254 are three. Each of the arm portions 252 has a first end 255, a second end 256, and a connecting section 257 between the first end 255 and the second end 256. The arm portion 252 is pivotally connected to the base 240 via a connection section 257. The cutters 254 are respectively mounted on the second ends 256 of the arm portions 252, and each of the cutters 254 rotates facing the axis A1. When the base 240 is pivoted by being driven by the motor 230, the rotation of the base 240 will generate a centrifugal force, and the connecting section 257 serves as a fulcrum of each of the arm portions 252 to pivot around the connecting section 257. Therefore, the first end 255 moves away from the axis A1, and the second end 256 with the cutter 254 moves toward the axis A1 to contact and peel off the coating. Therefore, a user can control the cutter 254 to remove (ie, strip) the cover of the electric wire 200 while the electric wire 200 continues to move forward along the axis A1.

The mobile holding assembly 120 can be configured to hold the electric wire 200 and move the electric wire 200 from one position to another. For example, the movable holding component 120 can hold a section of the electric wire 200 and move the above section from the cover removing component 110 to the deforming component 130. The mobile holding assembly 120 may include a bracket and a cutting unit for holding a small section of the electric wire 200. The cutting unit may be, for example, a blade for cutting the electric wire 200 and separating the electric wire 200 into two parts. . The mobile holding component 120 may include a track (not shown) that spans over the deformable component 130. The support and cutting unit of the movable holding component 120 can be moved along the track to move back and forth between the deformation component 130 and the cover removal component 110.

3 to 5 are top views of different steps performed by the deformed component 130 in the wire manufacturing system of FIG. 1. In some embodiments, the deformation component 130 may be configured to deform the electric wire 200 into a wave shape. In some embodiments, the deformation assembly 130 may include a plurality of partition plates 300 and a plurality of linear actuators 310. The separators 300 may be separated by a gap G1 therebetween and substantially parallel to each other. Each of the partition plates 300 may include a main body 410 and a bending member 420 (as shown in FIG. 4), where the bending member 420 is connected to the main body 410. The main body 410 may have two side edges 412 and 414 opposite and parallel to each other.

The bending member 420 may include a plurality of guide wheels 422 thereon. For example, each of the bending members 420 has three guide wheels 422 on top of the two partition plates 300 located at the farthest sides of the deformation assembly 130 on both sides. The three guide wheels 422 of each group located in the same bending member 420 together form a triangle. In detail, one set of guide wheels 422 on the same partition plate 300 is an upper guide wheel 422a and two bottom guide wheels 422b, and the bottom guide wheels 422b are located on opposite sides of the bending member 420. The triangular shape may be, but is not limited to, an isosceles triangle. In some embodiments, the wire 200 to be processed can be placed against the upper guide wheel 422a by the movable holding assembly 120.

The linear actuator 310 may be configured to enter a part of it into or out of the gap G1 between the partition plates 300 to push the electric wire 200 into a wave shape. In some embodiments, each of the linear actuators 310 includes a cylinder 312, a moving rod 314, and a bending member 316. In one embodiment, the linear actuator 310 can move the bending member 316 back and forth within the gap G1, respectively. As shown in FIG. 4, each of the bending members 316 is elongated and has three guide wheels 430 on its front end. The sets of guide wheels 430 of the same curved member 316 form an inverted triangle shape together. In detail, a group of guide wheels 430 on the bending member 316 has a bottom guide wheel 430a and two top guide wheels 430b disposed on opposite sides of the bending member 316. The aforementioned inverted triangle may be, but is not limited to, an isosceles triangle shape. The cylinder 312 is connected to one end of the moving rod 314 to drive the moving rod 314 to expand or contract within the range of the cylinder 312 and the gap G1. The bending member 316 is connected to the other end of the moving rod 314. When the cylinder 312 drives the moving rod 314 to extend toward the gap G1 (from the top to the bottom in FIG. 3), the bending member 316 moves downward. At the same time, a portion of the linear electric wire 200 facing the linear actuator 310 is pushed down by the bending member 316 to deform. Therefore, a portion of the linear electric wire 200 is transformed into a first group 341 U-shaped (ie, curved) portion 340 of one of the electric wires 200.

In addition, when the linear actuator 310 is operated to drive the bending member 316 into the gap G1, a portion of the electric wire 200 that is not deformed by the bending member 316 (for example, a portion not contacted by the guide wheels 430a, 430b) forms The two straight portions 330 on both sides (as shown in Figs. 3 and 4) are substantially parallel to each other. Both ends of each of the first group 341 of the U-shaped portions 340 formed by the curved member 316 are connected to the straight portion 330 of the electric wire 200.

As shown in FIGS. 3 and 4, on the other hand, when the bending member 316 enters the relative gap G1 between the bending members 420 of the partition 300 and the guide wheels 430a, 430b of the bending member 316 push the electric wire 20 to form the electric wire 200 At one time of the first group 341 of the U-shaped portions 340, another portion of the wire 200 is pushed to two adjacent bending members 420 and deformed (e.g., bent) into a second group of the U-shaped portions 340 342 of both. Accordingly, both of the straight portions 330 may connect one end of each of the first group 341 of the U-shaped portions 340 and one end of each of the second group 342 of the U-shaped portions 340. Therefore, the linear portions 330 and the U-shaped portions 340 which are alternately arranged with each other form a wave shape. The first group 341 and the second group 342 of the U-shaped portions 340 are formed on opposite sides of a neutral axis (not shown) of the wavy electric wire 200.

FIG. 6 is a top view of a leveling assembly 140 and a lifting assembly 160 of the wire manufacturing system 100 of FIG. 1. FIG. 7 is a partial cross-sectional view of the leveling assembly 140 of the wire manufacturing system 100 of FIG. 1. In some embodiments, the leveling assembly 140 may be configured to level multiple portions of the electrical wire 200 that are separated from each other. In an embodiment, the leveling assembly 140 may include a fixed stop 610 and a plurality of sliding stops 620. The fixed stop 610 is installed at a substantially middle position of the leveling assembly 140. The opposite sides of the block 610. The fixed stops 610 and the sliding stops 620 are arranged in a row and separated by a plurality of intervals G2, respectively. The sliding stop 620 can be configured to move toward or away from the fixed stop 610, so that when the sliding stop 620 moves, the width of the gap G2 changes accordingly. The fixing block 610 includes grooves 710 and 720 on opposite sides. Each of the sliding stops 620 may include a groove 730 located on one side facing away from the fixed stop 610. The grooves 710, 720, and 730 are respectively adjacent to the pitch G2. The grooves 710, 720, 730 may be configured to receive the straight portion 330 of the electric wire 200. The diameter of the wire 200 is larger than the width of the grooves 710, 720, 730. Therefore, when the straight portion 330 is placed in the grooves 710, 720, and 730, the straight portion 330 may occupy a portion of the entire grooves 710, 720, and 730 and the pitch G2.

In one embodiment, the side of the sliding stop 620 can be tapered from the bottom to the top to guide the linear portion 330 of the electric wire 200 into the grooves 710, 720, and 730. The edges of the sliding block 620 may be rounded.

In an embodiment as shown in FIG. 6, the leveling assembly 140 may further include two pushing units 630 and 632, which are respectively located on opposite sides adjacent to the entire set of sliding blocks 620. That is, the sliding stopper 620 and the fixed stopper 610 are located between the pushing units 630 and 632. The pushing units 630 and 632 are configured to push the sliding stopper 620 toward the fixed stopper 610 along one direction in which the electric wire 200 extends to flatten both sides of the linear portion 330 of the electric wire 200. As shown in FIG. 7, the direction in which the wire 200 extends is a horizontal direction, so the straight portion 330 can be horizontally squeezed by two relative forces F1 and F2, as shown in FIGS. 6 and 8, where FIG. 8 is an operation A partial cross-sectional view of the middle leveling assembly 140.

The leveling assembly 140 may further include a plurality of elastic units 740 positioned between each of the fixed stopper 610 and the sliding stopper 620 adjacent to each other. The elastic unit 740 is configured to apply a reaction force in response to one of the forces exerted by the two pushing units 630 and 632. For example, the pushing units 630, 632 may be linear drives driven by a motor.

In some embodiments, the lifting assembly 160 may be configured to move above the deforming assembly 130 and the leveling assembly 140 to transport the electrical wire 200 from the deforming assembly 30 to the leveling assembly 140. As shown in FIGS. 5 and 6, in some embodiments, the lifting assembly 160 may include a pair of claw portions 350 and a guide bar 360. The claw portions 350 are used to pick up and place the electric wire 200, and the guide rod 360 is coupled to the claw The portion 350 and the claw portion 350 can move along the guide rod 360. The lifting assembly 160 can be activated and moved downward to pick up the electric wire 200 from the deforming assembly 130 using the claw 350; the lifting assembly 160 can be moved above the leveling assembly 140 along the guide rod 360; the lifting assembly 160 can wave The straight portion 330 of the shaped wire 200 to the grooves 710, 720, and 730 of the leveling assembly 140 are shown in FIG.

As shown in FIG. 1, the wire making system 100 may further include a belt conveyor 170 adjacent to the leveling assembly 140. After the flattening assembly 140 flattens the straight portion 330 of the electric wire 200, the lifting assembly 160 can pick up the flattened electric wire 200 to the belt conveyor 170. The belt conveyor 170 can transport the finished wire 200 to a container (not shown) for the next step, for example, inserting the wire into a plurality of grooves of a certain core.

Next, a method for making a wire and a winding stator and a wire for a vehicle generator will be described. As shown in FIG. 2, first, the electric wire 200 is provided from the electric wire providing assembly 150 for substantially flattening a roll of the electric wire 200 to the straight electric wire 200. Furthermore, the first group of guide wheels 210 and the second group of guide wheels 220 can shape the electric wire 200 so that the electric wire is further linear. The electric wire 200 includes a core and a covering around one of the cores. In addition, as shown in FIG. 3, the electric wire 200 may be defined as a plurality of electric wire units, including a first electric wire unit 370 and a second electric wire unit 380. The second electric wire unit 380 extends from the first electric wire unit 370. Each of the first wire unit 370 and the second wire unit 380 has a first section 371, a second section 372, and a middle section 373 located between the first section and the second section. For example, as shown in FIG. 3, the first section 371 is located on the right side of the first wire unit 370 and the second section 372 is located on the left side of the first wire unit 370. The middle section 373 of the first wire unit 370 is located between the first section 371 and the second section 372. In some embodiments, when the first wire unit 370 is transported to the deformation assembly 130, the second wire unit 380 is transported to the cover removal assembly 110.

Next, as shown by the dotted line in FIG. 2, in a first position, a part of the covering of a first section 371 of a first wire unit 370 is removed. In some embodiments, the cover of the first section 371 is removed by the stripper 250 to expose the core of the first section 371. The exposed core is used for subsequent electrical connection in series or parallel to another wire. In addition, the end edge of the first section 371 is held by the mobile holding assembly 120 to hold the first wire unit 370 stably and horizontally.

Next, as shown in FIG. 3, the electric wire 200 is moved from the first position and held to a second position by the movable holding assembly 120. In some embodiments, the mobile holding assembly 120 holds the first section 371 of the first electric wire unit 370 to the right of the deforming assembly 130, and the middle section 373 of the electric wire 200 abuts the top of the partitions 300.

In addition, when it is necessary to remove a cover of a specific part of the electric wire 200, the parts of the electric wire 200 are passed through the stripper 250 while removing the cover. In some embodiments, when the mobile holding assembly 120 moves the wire 200 from the first position to the second position, the stripper 250 can remove the covering of the second section 372 of the first wire unit 370 and connect the first wire unit 370. Part of the second electric wire unit 380 of the second paragraph 372 mentioned above.

Next, the linear driver 310 is driven to push the bending member 316 to deform the electric wire 200 to form a plurality of U-shaped portions 340. In addition, a plurality of linear portions 330 are formed along the sides of the curved member 316. In some embodiments, from the right side to the left side of FIG. 4, the bending member 316 is defined to have a first bending member 316a (ie, the rightmost bending member), a second bending member 316b, and a third bending member 316c. ... an Nth bending member 316N (ie, the leftmost bending member).

In this step, by moving the bending member 316 of the linear actuator 310, the portions of the middle section 373 that are separated from each other can be sequentially pushed from one side of the first section 371 to one side of the second section 372. In order to enter the gaps G1 between the partition plates 300, respectively. In some embodiments, the first bending member 316a corresponds to the first section 371, and the last (Nth) bending member 316N (ie, the leftmost bending member) corresponds to the second section 372, except for the first bending member Except for 316a and the Nth bending member 316N, the remaining bending members 316 correspond to the middle section 373. In one embodiment, the second bending member 316b (ie, the second bending member on the right) is first pushed to the electric wire 200. At this time, since the first section 370 of the electric wire 200 is tightly held by the movable holding assembly 120, when the second bending member 316b pushes the electric wire 200, only the left side of the electric wire 200 is pulled into the gap G1. This is because the longitudinal deformation of the wire 200 is restricted, and if the left side (second section 372) of the wire 200 is tightly held, when a part of the wire 200 is pushed into the gap G1, the wire 200 may cause unwanted Deformed, or even cut into two sections. Therefore, one side of the electric wire 200 should be slack to prevent the electric wire 200 from being damaged. On the other hand, if both ends of the first electric wire unit 370 are not held (forming a free end), when the curved part 316 of the linear actuator 310 pushes the electric wire unit 370, it is difficult for the user to accurately and accurately predict The segments form a plurality of straight portions 330 and a plurality of U-shaped portions 340.

In some embodiments, when the second bending member 316b is moved into the gap G1 to push the electric wire 200, the third bending member 316c located on the left side of the second bending member 316b is moved into the corresponding gap G1. . Then, after the third bending member 316c stops moving, the fourth bending member 316d located on the left side of the third bending member 316c is moved into the corresponding gap G1. As shown in FIG. 4, from the right to the left, the other bending members 316 are sequentially moved into their respective corresponding gaps G1 until the N-1th bending member 316 (N-1) is moved to it. Within the corresponding gap G1. When the adjacent two bending members 316 (for example, the second bending member 316b and the third bending member 316c) are moved into the corresponding gap G1, the bending member 420 corresponding to the partition 300 is formed. The second group 342 of the U-shaped portion 340. At this time, the step of deforming the middle section 373 of the first electric wire unit 370 to form a straight portion 330 and a U-shaped portion 340 that alternate with each other is completed.

After the second bending member 316b is moved into the gap G1, the right end of the middle section 373 of the first wire unit 370 is held by the second bending member 316b. At this time, the mobile holding assembly 120 can release the first section 371 of the first wire unit 370. Since the second bending member 316b has replaced the mobile holding unit 120 to hold the right side of the first wire unit 370, the mobile holding unit 120 can Moving from the right side of the deformed component 130 over the deformed component 130 to the left, and holding the second section 372 of the first electric wire unit 370.

As shown in FIG. 5, after that, the movable holding assembly 120 can cut the connection between the second section 372 of the first electric wire unit 370 and the second electric wire unit 380 to separate the first electric wire unit 370 from the second electric wire. Unit 380. At this time, the mobile holding assembly 120 does not hold the second section 372 of the first wire unit 370; the first section 381 of the second wire unit 380 is still held by the mobile holding module 120. In other words, in addition to being held by the movable holding assembly 120, both ends of the first wire unit 370 are held by the first bending member 316a and the Nth bending member of the deformation assembly 130 in the gap G1, respectively. Furthermore, in some embodiments, when the second section 372 of the first electric wire unit 370 and the first section 381 of the second electric wire unit 380 pass through the cover removal assembly 110, the second section 372 of the first electric wire unit 370 The cover of the first section 381 of the second wire unit 380 and the cover of the first section 381 of the second wire unit 380 are removed, so that the cores of the second section 372 of the first wire unit 370 and the first section 381 of the second wire unit 380 are exposed to electricity Connect other wire units.

Furthermore, the first bending member 316a and the Nth bending member 316N push the first section 371 and the second section 372 of the first wire unit 370 to form both ends of the first wire unit 370 to the U-shaped portion 340 and Straight portion 330. At this time, both ends of the first wire unit 370 are not held by the movable holding assembly 120, so both ends of the first wire unit 370 can be pushed to the first bending member 316a and the Nth bending member 316N. Within its corresponding gap G1. Therefore, the steps of deforming the middle section 373, the first section 371, and the second section 372 to form the first wire unit 370 into a wave shape are completed.

In one embodiment, the pushing steps of the first bending member 316a and the Nth bending member 316N can be performed simultaneously. In other embodiments, the first bending member 316a and the Nth bending member 316N may perform the aforementioned pushing step one by one.

After that, as shown in FIGS. 5 to 6, the claw portion 350 of the lifting assembly 160 can pick up the first wire unit 370 from the deforming assembly 130 and move it along the guide bar 360 to the leveling assembly 140. Then, the claw portion 350 can place the linear portion 330 of the first wire unit 370 into the grooves 710, 720, and 730, as shown in FIG.

The straight portion 330 of the middle section 370 may be flattened along the direction in which the electric wire 200 extends. In some embodiments, two forces F1, F2 are applied to the two pushing units 630, 632 on both sides of the leveling assembly 140 to push the sliding stop 620 toward the fixed stop 610. The distance G2 between two adjacent sliding stops 620 or between the fixed stop 610 and its adjacent sliding stop 620 will be reduced to zero, so that the sliding stop 620 can press the sides of the linear portion 330. The straight portion 330 is extruded to flatten its cross section. In some embodiments, the cross-section of the straight portion 330 is reshaped from a circle to form a square or oval shape. In other embodiments, the cross section of the linear portion 330 may be shaped into other shapes. In some embodiments, since the cross-sections of the linear portions 330 have been leveled, when the linear portions 330 are continuously arranged in the grooves of a certain core, the shape of the flattened linear portions 330 can better match. The shape of the groove to reduce the air gap in the groove. In addition, compared with the conventional electric wire 200 having a circular straight portion, the aforementioned slot can accommodate more electric wires 200 with a flattened straight portion 330 to increase the strength of the magnetic field. Therefore, the magnetic resistance generated by the air gap can be reduced, thereby reducing the overall magnetic resistance.

In some embodiments, the leveling assembly 140 includes two pushing units 630 and 632, which are respectively disposed on opposite sides of the body of the leveling assembly 140. If there is only one pushing unit disposed on one side of the leveling assembly 140, the pushing unit needs a large force to push all the sliding stops 620 from one side to the opposite side, thereby leveling all the linear portions 330. Compared with a single pushing unit system, each of the pushing units 630 and 632 in this embodiment only needs to push half of the sliding stopper 620 and move toward the fixed stopper 610 located around the middle section of the leveling assembly 140 Therefore, only a small force needs to be applied. Furthermore, compared with the system of a single pushing unit, the working distance of the two pushing units 630, 632 is shorter, so the speed of leveling the wire 200 in this system is faster than the speed of the system of a single pushing unit.

As shown in FIGS. 6 and 8, when the pushing units 630 and 632 apply the forces F1 and F2 to push the sliding stopper 620 toward the fixed stopper 610, they are positioned between or between the fixed stopper 610 and the sliding stopper 620. The elastic unit 740 between the adjacent sliding blocks 620 is also compressed. When the two pushing units 630 and 632 stop pushing the sliding stopper 620 and return to the original position, each of the elastic units 740 can exert a reaction force in response to the force exerted by the two pushing units 630 and 632, thereby pushing all Slide the stopper 620 to return to the original position.

As shown in FIG. 6, after the straight portion 330 of the first electric wire unit 370 is leveled, the lifting assembly 160 can pick up the first electric wire unit 370 from the leveling unit 140 to the belt conveyor 170. The belt conveyor 170 carries the first electric wire unit 370 to a container (not shown) for the next manufacturing process, for example, the first electric wire unit 370 is wound onto a certain core.

In addition, when the leveling assembly 140 is leveling the straight portion 330 of the first electric wire unit 370, the deforming unit 130 can simultaneously perform the steps of deforming the second electric wire unit 380, and the cover removing unit 110 can be simultaneously received from the second electric wire unit. A third wire extends from the other end of the 380. Therefore, the electric wire production system 100 can simultaneously execute multiple steps of different electric wires provided on different workstations of the electric wire production system 100, thereby increasing production efficiency.

FIG. 9 is a perspective view of a winding stator with a wire unit 900 manufactured by the wire manufacturing system 100 according to an embodiment of the disclosure. Each of the electric wire units 900 may be inserted into a plurality of slots 910 of the stator core 920. For example, the stator core 920 has 96 slots 910 that are evenly formed on the inner torus of the stator core 920. For example, in a wire unit, the number of the first group 341 of the U-shaped portion 340 is 16 and the number of the second group 342 of the U-shaped portion 340 is 15. Half of the electric wire unit 900 may be inserted into the groove 910 with a gap. Then, the other half of the wire unit 900 may be reversed to another opposite direction and inserted into the groove 910. This means that the same wire unit 900 can be repeatedly inserted into the same slot 910. Furthermore, each of the slots 910 can accommodate a plurality of different wire units 900, for example, two or more wire units.

Therefore, in one embodiment of the present disclosure, a wire making device can automatically make a coil of wire into a plurality of wavy wires, so that it has a plurality of flattened straight portions and a plurality of U-shapes. section. Factory employees do not need to continue to focus on making wires after a long working time, resulting in inconsistent quality, which reduces the power generation efficiency of manual stators. Therefore, after reducing the manual process, the wires manufactured by the aforementioned wire manufacturing apparatus and method can provide better quality of the stator and power generation efficiency.

Furthermore, according to an embodiment of the present disclosure, when the electric wires are automatically cut into a plurality of electric wire units, the lengths of the respective electric wire units will be the same. It is known that the method of manually cutting the electric wire and removing the covering of the electric wire often causes the problem of inconsistent length of the electric wire unit, thereby causing waste of electric wire material. On the contrary, since the present disclosure provides a way to accurately cut the wires, waste of wire materials is avoided.

Furthermore, the step of removing the cover is performed before the wire is deformed into a wave shape, and the cover removing component can remove one end of the wire unit and one end of the other wire unit at the same time, which will save working time. Compared with the conventional way of removing the cover manually, the removal of the cover in this disclosure can be more consistent.

The above-mentioned embodiments are only for explaining the technical ideas and characteristics of this disclosure, and the purpose is to enable those skilled in the art to understand the content of this disclosure and implement it accordingly. When the scope of patents of this disclosure cannot be limited, Equivalent changes or modifications made in accordance with the spirit disclosed in this disclosure should still be covered by the patent scope of this disclosure.

100‧‧‧Wire making system

110‧‧‧ Cover removal components

120‧‧‧ Mobile holding components

130‧‧‧Transformer

140‧‧‧leveling components

150‧‧‧Wire supply components

160‧‧‧Lifting kit

170‧‧‧Belt Conveyor

200‧‧‧Wire

210‧‧‧The first set of guide wheels

220‧‧‧The second set of guide wheels

230‧‧‧ Motor

232‧‧‧channel

240‧‧‧ base

250‧‧‧ Stripper

252‧‧‧arm

254‧‧‧Cutter

255‧‧‧ the first end

256‧‧‧ the second end

257‧‧‧connection section

300‧‧‧ bulkhead

310‧‧‧ Linear Drive

312‧‧‧cylinder

314‧‧‧move

316‧‧‧Bent parts

316a‧‧‧First curved part

316b‧‧‧Second bending part

316c‧‧‧Third bending part

316 (N-1) ‧‧‧The N-1th curved part

316N‧‧‧Nth curved part

330‧‧‧Straight part

340‧‧‧U-shaped section

341‧‧‧Group 1

342‧‧‧Group 2

350‧‧‧Claw

360‧‧‧Guide

370‧‧‧First Wire Unit

371‧‧‧first paragraph

372‧‧‧paragraph 2

373‧‧‧ middle section

380‧‧‧Second wire unit

381‧‧‧ first paragraph

410‧‧‧Subject

412, 414‧‧‧

420‧‧‧Bent parts

422‧‧‧Guide Wheel

422a‧‧‧ Upper guide wheel

422b‧‧‧Bottom guide wheel

430‧‧‧Guide Wheel

430a‧‧‧Bottom guide wheel

430b‧‧‧guide wheel

610‧‧‧Fixed stop

620‧‧‧Sliding stop

630, 632‧‧‧ push unit

710, 720, 730‧‧‧ groove

900‧‧‧Wire unit

910‧‧‧slot

920‧‧‧Stator core

A1‧‧‧Axis

F1, F2‧‧‧force

G1‧‧‧ Clearance

G2‧‧‧Pitch

In order to understand the effect of the present invention and its advantages more clearly, the present invention is described in detail with reference to the accompanying drawings and in the form of embodiments.

FIG. 1 is a top view of a wire manufacturing system according to an embodiment of the disclosure.

FIG. 2 is an enlarged plan view of a wire providing component, a cover removing component, and a mobile holding component of the wire manufacturing system of FIG. 1. FIG.

FIG. 3 is a top view of the wire manufacturing system of FIG. 1, in which a deformed component is in an operating state.

4 and 5 are other top views of the electric wire manufacturing system of FIG. 1, in which the deformed component is in an operating state.

FIG. 6 is a top view of a leveling component and a lifting component of the wire manufacturing system of FIG. 1. FIG.

FIG. 7 is a partial cross-sectional view of a leveling assembly of the wire manufacturing system of FIG. 1. FIG.

Fig. 8 is a partial sectional view showing the operation of the leveling assembly.

FIG. 9 is a perspective view of a winding stator of an electric wire made according to an embodiment of the present disclosure.

Claims (20)

A device for making a wire for a winding stator and a wire of a vehicle generator. The wire includes a core and a cover surrounding the core. The device includes: A cover removal component configured to remove the cover in a first position; A mobile holding component configured to hold and move the wire from the first position to a second position; A deformed component configured to deform the wire into a wave shape; and A leveling assembly configured to level out portions of the wire that are separated from each other. The device of claim 1, further comprising a wire providing assembly configured to provide and transport the wire. The device of claim 1, wherein the deformation assembly includes a substrate, a plurality of partitions on the substrate, and a plurality of linear actuators, and the partitions are separated from each other by a gap therebetween and are substantially parallel to each other. The device of claim 3, wherein the linear actuator includes a cylinder, a moving rod, and a bending member, wherein the bending member is an elongated shape, and the cylinder is connected to one end of the moving rod to drive the moving rod between the cylinder and the cylinder. The range between the gaps is extended or contracted, and the curved member is connected to the other end of the moving rod and is configured to deform the electric wire to form a first group of U-shaped portions. The device of claim 4, wherein each of the partitions includes a main body and a bending member, the bending member is connected to the main body, the main body has two sides opposite to each other, the folding member of the partition and The curved part of the linear actuator includes a plurality of guide wheels. The device of claim 5, wherein when the bent member is driven to enter the gap between two adjacent bent members of the partition, a part of the electric wire is pushed by the bent member to form the electric wire. One of the first group of U-shaped portions, and the other portion of the electric wire is pushed against the adjacent two of the bent parts to form the second group of U-shaped portions. If the device of claim 5, wherein each of the bent parts and each of the bent parts includes three guide wheels to guide the wire to be bent, the bent parts and the groups of the bent parts The three guide wheels form a triangle or an inverted triangle. The device of claim 1, wherein the leveling assembly includes a bottom plate, a fixed stop, and a plurality of sliding stops, the fixed stop is installed approximately in the middle of the bottom plate, and the plurality of sliding stops are disposed on the bottom plate And are located on both sides of the fixed stop, wherein the fixed stop and the sliding stop are arranged in a row and separated from each other by the grooves, each of the grooves is configured to receive the electric wire The straight parts. The device of claim 8, wherein the leveling assembly further includes two pushing units, which are respectively located on opposite sides of the bottom plate, and the two pushing units are configured to follow one direction of the electric wire to face the fixed stop. The sliding block is pushed by the block, thereby flattening the linear portions. The flattening assembly further includes a plurality of elastic units located between the fixed block and the adjacent two of the multiple sliding blocks. The isoelastic unit is configured to exert a reaction force in response to one of the forces exerted by the two pushing units. The device as claimed in claim 8, wherein the sides of the sliding stops are tapered in a direction away from the bottom plate to guide the insertion of the electric wires. The device of claim 1, wherein the cover removal assembly includes a stripper and a motor, the stripper includes an arm portion and a cutter, the cutter is installed at one end of the arm portion, and the motor is configured to The stripper is driven to rotate to allow the cutter to move toward the central axis of the stripper by a centrifugal force generated by the rotation. The device of claim 1, further comprising a lifting component configured to transport the wire from the deformed component to the leveling component. A method for manufacturing a winding stator and a wire of a vehicle generator, the method includes: Removing a covering of a first segment of the wire at a first position; Moving the wire from the first position to and holding it in a second position; Transforming a middle section of the electric wire into a wave shape, so that the electric wire forms a plurality of straight portions and a plurality of U-shaped portions that are staggered with each other; Removing the covering of a second section of the wire at the first position, the middle section connecting the first section and the second section; Cut off the wire to separate the first section, the middle section and the second section of the wire from other parts of the wire; and The first segment and the second segment are transformed into a wave shape. The method of claim 13, further comprising flattening the straight portions of the middle section along a direction in which the electric wire extends. A method for manufacturing a winding stator and a wire of a vehicle generator, the method includes: Provided is an electric wire including a core and a cover surrounding the core, the wire is defined to have a first wire unit and a second wire unit, the first wire unit having a first section, a second section, and An intermediate segment between the first and second segments; Removing the covering of the first paragraph to expose the core of the first paragraph; Hold on to the first paragraph; The multiple sections of the intermediate section that are separated from each other are pushed to deform the intermediate section to form a plurality of intersecting linear sections and a plurality of U-shaped sections, thereby forming a wave shape; Remove the cover at one end of the second paragraph; Cutting the electric wire to separate the first electric wire unit from the second electric wire unit; Pushing the first and second paragraphs to make the first and second paragraphs wavy, respectively; and Squeeze the straight sections to flatten their cuts. The method of claim 15, wherein the step of pushing the intermediate section apart from each other to deform the intermediate section to form the interlaced straight portions and the U-shaped portions, and then forming a wave-like step is more contain: The sections of the middle section are sequentially pushed from the side of the first section to the side of the second section. The method of claim 16, wherein the step of pushing the intermediate sections apart from each other to deform the intermediate sections to form the interlaced straight portions and the U-shaped portions, thereby forming a wavy step is more contain: By moving the curved parts of the linear actuators into the gaps between the partitions, the middle segment is sequentially pushed from the side of the first segment to the side of the second segment. Those parts. The method of claim 15, wherein the step of removing the cover at the end of the second paragraph includes: Simultaneously remove the covering at the end of the second section of the first wire unit and the first section of the second wire unit extending from the second section of the first wire unit. The method of claim 15, wherein before the steps of pushing the first paragraph and the second paragraph to transform the first paragraph and the second paragraph into a wave shape, respectively, further comprising: Release the first paragraph. The method of claim 15, wherein the step of squeezing the straight portions to level the cut surface further includes: The straight portions are squeezed in a direction in which the electric wire extends.