WO2020140504A1

WO2020140504A1 - Flat-wire bending apparatus for flat-wire motor winding

Info

Publication number: WO2020140504A1
Application number: PCT/CN2019/108817
Authority: WO
Inventors: 林中尉
Original assignee: 苏州阿福机器人有限公司
Priority date: 2018-12-30
Filing date: 2019-09-28
Publication date: 2020-07-09
Also published as: CN109746345B; CN109746345A

Abstract

A flat-wire bending apparatus for a flat-wire motor winding is capable of bending flat wires of different bending angles and bending lengths in a winding layer at one time, and prevents the flat wires from deforming in thickness directions thereof. The apparatus comprises rotary sleeves (11, 21) and a driving apparatus. A flat-wire I holding slot (2131) is provided at the outer periphery of the rotary sleeves (11, 21). Each pair of flat-wire I holding slots (1131, 2131) is oppositely disposed at end portions of part or all of the flat wires. When the rotary sleeve is moved axially towards an end portion of an iron core, end portions of the flat-wire I extend into the oppositely disposed flat-wire I holding slots. When the rotary sleeves (11, 21) rotate, the flat-wire I bends in a circumferential direction of the iron core. The outer periphery of flat wires on the same circumference is surrounded by guide sleeves (12, 22). The outer periphery of the guide sleeves (12, 22) contacts outer sides of the flat wires in a radial direction so as to prevent the flat wires from deforming outwards in a radial direction of the stator iron core during bending of the flat wires. Position-limiting sections (112, 212) are connected to holding sections (113, 213). The outer periphery of the position-limiting sections (112, 212) contacts inner sides of the flat wires in the radial direction so as to prevent the flat wires from deforming inwards in the radial direction of the stator iron core during the bending of the flat wires.

Description

Device for bending flat wire in flat wire motor winding

Technical field

The technology relates to the field of motor manufacturing, and provides a device for bending a flat wire, in particular, a device for bending a flat wire in a flat wire motor winding. Using the device to bend a flat wire, it can be bent at once A flat wire with different bending angles and bending lengths in one winding layer can effectively prevent the flat wire from being deformed in the thickness direction of the flat wire, which is beneficial to reduce the skin effect of the bent portion of the flat wire.

Background technique

Compared with windings made of round wires with a circular cross section, motor windings made of rectangular wires with a rectangular cross section (hereinafter referred to as flat wires) have the characteristics of high slot full rate and good heat dissipation. Therefore, flat wires are used Making motor windings has become the industry's development direction. However, the strength of the flat wire in the width direction is higher than that of the round wire, and it is difficult to bend, which is one of the difficulties in the production of flat wire motor windings.

When the wire is bent, the general process is: after passing the flat wire into the stator core, or one end of the flat wire passing through the iron core, or both ends need to be bent along the circumferential direction of the winding layer where the flat wire is located, and folded The end of the bent flat wire is parallel to the axis of the stator core.

In general, the winding layers on both ends of the iron core are different, one end is the uniform end YZ, and the other end is the difference end CY.

The uniform end YZ refers to the height of all the flat wire bending angles and the height after the flat wire is bent when the end of the extended core is bent in the circumferential direction (the distance from the end of the flat wire in the axial direction of the core to the end surface of the core ) One end of the same winding layer. The device for bending the flat wire at the uniform end YZ is the uniform end tooling.

When the flat wire protruding from one end of the iron core is bent along the circumferential direction, due to requirements such as bridging, the bending angle of a few flat wires is different from the bending angle of most flat wires, and the height of a few flat wires after bending ( The distance from the end of the flat wire in the axial direction of the core to the end face of the core is higher than the height of most flat wires after bending. This end of the winding layer is the difference end CY. The device for bending the flat wire at the differential end CY is the differential end tooling.

In the motor winding R in the stator core T, generally, a rectangular wire B having a width k and a thickness h on the same radius is called a winding layer C, and the inner diameter of the winding layer is J ₁ and the outer diameter is J ₂ . A flat wire B in a winding layer C. The angle change of the end of the flat wire B relative to the initial position of the flat wire B in the circumferential direction of the winding layer C is called the bending angle D of the flat wire. The height of the wire B (the distance from the end of the flat wire in the axial direction of the core to the end face of the core) is called the bending height H; most flat wires with the same bending angle D _{1 and the} same height as the bending height H _{1 are} called flat Line I01; the few flat lines whose bending angle D _{2 is} smaller than the bending angle D ₁ of the flat line I01 are called flat line II02 (in most cases, the bending height H ₂ of flat line II02 and the bending height H _{1 of} flat line I01, etc. High); the bending angle D _{3 is} smaller than the bending angle D _{1 of the} flat line I01 but greater than the bending angle D ₂ of the flat line II02. The few flat lines are called flat line III03 (in most cases, the bending height of flat line III03 is H _{3 is} greater than the bending height of the flat wire I01 (H ₁ ); that is: D ₁ > D ₃ > D ₂ ; and in general, H ₃ > H ₁ = H ₂ . Flat wire I01, flat wire II02 and flat wire III03 are collectively called flat wire B.

Conventionally, the bending direction of the flat wire B is based on the bending end visually. Due to the large number of wire slots in the stator core, for the convenience of construction, in the prior art, the wire slots or the flat wires B in the wire slots are numbered clockwise, and this number is called a flat wire serial number.

When the wire works in a high-frequency electrical environment and there is alternating current or alternating electromagnetic field in the wire, the current inside the wire is unevenly distributed, and the current is concentrated on the "skin" part of the wire, that is, the current is concentrated on the thin layer of the wire surface, the closer to On the surface of the wire, the greater the current density, the smaller the current inside the wire, which increases the impedance of the wire and increases the power loss. This kind of skin effect exists objectively. When the thickness of the wire exceeds a certain value, the actual resistance of the wire will increase, resulting in a decrease in the efficiency of the winding. Therefore, the thickness of the wire should not exceed the thickness that produces a larger skin effect (can According to the carrier frequency calculation), this principle can be simply understood as the smaller the thickness of the flat wire, the smaller the skin effect.

However, the smaller the thickness of the flat wire, the greater the difficulty of bending along the width direction, because the flat wire is easily deformed in the thickness (smaller size) direction, but not in the width (larger size) direction. What is needed when bending the flat wire in the process is to not allow the flat wire to deform in the thickness direction but to deform in the width direction.

Summary of the invention

The purpose of this technology is to provide a device for bending a flat wire in a flat wire motor winding. Using the device to bend a flat wire, a flat wire at the same end of a winding layer can be bent at a time, and the bending angle of each flat wire is the same 1. The bending height is consistent and the working efficiency is high. It is also possible to bend a flat wire with different bending angles and bending lengths at the different ends of a winding layer at a time, which effectively prevents the flat wire from deforming in the direction of the thickness of the flat wire, which is beneficial to reduce The skin effect of the bend of the small flat wire.

The purpose of this technology is to achieve through the following technical solutions:

The device for bending a flat wire in a flat wire motor winding described in this patent includes a rotating sleeve, a driving device that drives the axial movement of the rotating sleeve and rotates about an axis, and a flat wire I holding slot is provided on the outer periphery of the rotating sleeve , Each flat wire I holding slot is axially opposed to the ends of some or all of the flat wires passing through the same circumference of the core of the flat wire motor winding in the axial direction; axially opposite to the flat wire I holding slot The flat wire is called flat wire I; when the rotating sleeve moves axially to the end of the iron core, the end of the flat wire I can extend into the opposite flat wire I holding groove; when the rotating sleeve rotates, the end The flat wire I extending into the holding groove of the flat wire I is bent in the circumferential direction of the core; on the same circumference, the outer circumference of the flat wire surrounds the guide sleeve, and the outer circumference of the guide sleeve is on the same diameter as the flat wire on the same circumference. Contact outward in the direction to prevent the flat wire from deforming radially outward in the stator core when it is bent; the limit section is connected to the holding section, and the outer circumference of the limit section is the same as the flat wire on the same circumference Contact inside in the radial direction to prevent the flat wire from deforming radially inward in the stator core when it is bent.

Beneficial effect of this patent: Since the holding groove of each flat wire I is provided with a rotating sleeve together, the rotation of the rotating sleeve can simultaneously bend the flat wire I, so that the bending angle of each flat wire I is the same, and the production efficiency is high . During the rotation of the rotary sleeve, the flat wire is gradually shortened in the axial direction because the flat wire is bent in the circumferential direction. If the rotary sleeve only rotates without moving axially toward the end of the core, the flat wire will gradually change from flat The wire I card slot comes out. Therefore, during the rotation of the rotating sleeve, it also needs to move toward the end of the iron core.

This patent uses a guide sleeve and a limit section to ensure that the thin wire is bent in the width direction of the thin wire (flat wire) and the thin wire does not warp in the thickness direction. The thin wire can avoid the skin effect, which is different from other technologies in this patent One of the keys.

The device for bending a flat wire can be used for bending a flat wire at a uniform end of a winding layer, and can also be used for bending a flat wire at a different end of a winding layer. For the convenience of explanation, the device that bends the flat wire at the uniform end of the winding layer is called the uniform end tooling, and the device that bends the flat wire at the different end is called the differential end tooling. For the uniform-end tooling, each flat wire I holding groove is opposed to the end of all the flat wires on the same circumference passing through the iron core of the flat wire motor winding in the axial direction. For the differential-end tooling, each flat wire I holding slot is opposed to the end of a part of the flat wire passing through the same core of the core of the flat wire motor winding in the axial direction.

As a further improvement to the above-mentioned device for bending a flat wire in a flat wire motor winding, each flat wire I holding groove and the end of a part of the flat wire passing through the iron core in the flat wire motor winding are in the axial direction In a one-to-one relationship, the flat wires other than flat wire Ⅰ are called residual flat wires; the portion of the sleeve that is provided with flat wire Ⅰ holding grooves is called the holding section; there is a stagnation in the circumferential direction on the holding section Slot, a flat wire III insert slides in the circumferential direction of the sleeve, and is fixedly arranged in a stagnation groove in the axial direction of the sleeve; from the wall of the stagnation groove to the flat wire Ⅲ insert opposite to it in the circumferential direction The center angle between the sides of the block is x°; the outer side of the flat wire III block is provided with a flat wire III holding groove, each flat wire III holding groove and the end of some or all of the remaining flat wires are in the axial direction One by one; the remaining flat wire axially opposed to the flat wire III holding groove is called flat wire III; when the rotating sleeve moves toward the end of the iron core in the axial direction, the end of the flat wire III can extend into the opposite flat wire In the line III holding groove; when the rotation angle of the rotary sleeve is z°≤x°, the rotary sleeve rotates in the circumferential direction relative to the flat line III block, and the flat line III block does not rotate; when the rotary sleeve rotates angle z°>x When °, the wall of the lagging slot is in contact with the side of the flat line III block. The rotating sleeve drives the flat line III block to rotate around the axis. The angle of rotation of the flat line III block is y°=z°-x°; when the flat line When the Ⅲ insert rotates, the flat wire III extending into the holding groove of the flat wire III is bent in the circumferential direction of the iron core.

After this improvement, the device used for bending the flat wire in the winding of the flat wire motor (in this case, the differential end tooling) can not only bend most flat wires I at one time, but also bend a small number of flat wires. Line III makes a one-time bend. The bending angle D ₁ of most flat wires I is z°, and the bending angle D ₃ of a small portion of flat wires III is y°, z°-y°=x°; since the rotating sleeve rotates x°, the flat wire III The insert only rotates with the rotary sleeve, so x° is the set angle of the flat wire III relative to the stagnation of the rotary sleeve. It can also be said that the bending angle of the flat wire III is the bending angle of the flat wire I and the flat The difference between the setting angle of the line III insert block and the lagging of the rotary sleeve.

The direction of rotation of the rotary sleeve is not limited, and it can rotate clockwise or counterclockwise, as described below.

If the angle of the center of the circle from the wall of the stagnation groove in the clockwise direction to the side of the flat line III opposite to the circumferential direction is x°; when the rotating sleeve rotates clockwise at an angle of z°≤x°, the rotating sleeve is opposite When the flat block of the flat wire III rotates in the circumferential direction, the flat block of the flat wire III does not rotate; when the rotating sleeve rotates clockwise at an angle of z°>x°, the wall of the stagnation groove contacts the side of the flat block of the flat wire III, and the rotary sleeve drives The flat wire III inserts rotate together clockwise around the axis, and the angle of rotation of the flat wire III inserts y°=z°-x°; when the flat wire III inserts rotate clockwise, the end extends into the flat wire III to hold The flat wire III in the groove is bent clockwise in the circumferential direction of the iron core.

If the angle of the center of the circle from the wall of the stagnation groove in the counterclockwise direction to the side of the flat line III opposite to the circumferential direction is x°; when the rotation sleeve rotates counterclockwise at an angle of z°≤x°, the rotation sleeve is opposite When the flat block III rotates in the circumferential direction, the flat block III does not rotate; when the rotating sleeve rotates counterclockwise at an angle of z°>x°, the wall of the hysteresis groove contacts the side of the flat block III and the rotating sleeve drives The flat wire III block rotates counterclockwise around the axis, and the angle of the flat wire III block rotates y°=z°-x°; when the flat wire III block rotates counterclockwise, the end extends into the flat wire III to hold The flat wire III in the groove is bent counterclockwise in the circumferential direction of the iron core.

As a further improvement to the above-mentioned device for bending the flat wire in the winding of the flat wire motor, there is a step inside the holding section of the rotating sleeve, and the flat wire Ⅲ rotating in axial contact with the step is set inside the holding section , The flat wire III insert is set on the outer circumference of the flat wire III turn.

This improvement enables each flat wire III insert to rotate synchronously, and at the same time, the step limits the axial limit of the flat wire III rotating ring, preventing the movement of the flat wire III rotating ring and flat wire III insert relative to the rotating sleeve in the axial direction. It can also make the flat wire III rotation circle and flat wire III inserts rotate flexibly in the circumferential direction.

As a further improvement to the above-mentioned device for bending the flat wire in the winding of the flat wire motor, each flat wire III holding groove is opposed to the end of part of the remaining flat wire in the axial direction, except for the flat wire III The remaining flat wire is called flat wire II; a flat wire II insert slides in the circumferential direction of the rotating sleeve and is fixedly arranged in a stagnation groove in the axial direction of the rotary sleeve; flat wire III insert and flat wire II The insert is located in a stagnation groove; the center angle between the side of the flat wire III insert and the side of the flat wire II opposite to it in the circumferential direction is u°; the outer side of the flat wire II insert is provided with a flat wire II holding groove, each flat wire II holding groove is opposite to the end of the flat wire II one by one in the axial direction; when the rotating sleeve moves to the end of the iron core in the axial direction, the end of the flat wire II can extend into Relative flat wire II holding groove; when the rotation angle of the flat wire III insert is y°≤u°, the rotating sleeve and the flat wire III insert rotate relative to the flat wire II insert, and the flat wire II insert No rotation; when the rotation angle of the flat wire III insert is y°>u°, the side of the flat wire III insert is in contact with the side of the flat wire II insert. The rotating sleeve and flat wire III insert drive the flat wire II insert around the axis together Rotate, the angle of the flat wire II insert rotates v°=y°-u°; when the flat wire II insert rotates, the flat wire II that extends into the holding groove of the flat wire II is bent in the circumferential direction of the iron core .

After this improvement, the device for bending the flat wire in the flat wire motor winding (in this case, the differential end tooling) can not only bend most flat wires I and a small number of flat wires III at one time. , A small part of the flat wire II can be bent at one time. The bending angle D ₃ of a small part of the flat wire III is y°, and the bending angle D ₂ of the small part of the flat wire II is v°, and y°-v°=u°; The flat wire II block only rotates with the flat wire III block, so u° is the stagnation set angle of the flat wire II block relative to the flat wire III block. It can also be said that the bending angle of the flat wire II is The difference between the bending angle of the flat wire III and the sluggish setting angle of the flat wire II insert relative to the flat wire III insert.

As described above, the direction of rotation of the rotary sleeve is not limited, and it can be rotated clockwise or counterclockwise, as described below.

If the flat line III block and the flat line II block are located in a stagnation groove in a clockwise direction; from the side of the flat line III block in the clockwise direction to the side of the flat line II block opposite to it in the circumferential direction The angle of the center of the circle is u°; when the flat wire III block rotates clockwise at an angle of y°≤u°, the rotary sleeve and flat wire III block rotate relative to the flat wire II block, and the flat wire II block Does not rotate; when the flat wire III block rotates clockwise at an angle of y°>u°, the side of the flat wire III block contacts the side of the flat wire II block, and the rotary sleeve and flat wire III block drive the flat wire II block together Rotate around the clockwise axis, the angle of the flat wire II insert rotates v°=y°-u°; when the flat wire II insert rotates clockwise, the end extends into the flat wire II holding groove of the flat wire II Bend in the circumferential direction of the iron core.

If the flat line III block and the flat line II block are located in a stagnation groove in the counterclockwise direction; from the side of the flat line III block in the counterclockwise direction to the side of the flat line II block opposite to it in the circumferential direction The center angle of u is u°; when the flat wire III block rotates counterclockwise at an angle of y°≤u°, the rotary sleeve and flat wire III block rotate relative to the flat wire II block, and the flat wire II block Does not rotate; when the flat wire III block rotates counterclockwise at an angle of y°>u°, the side of the flat wire III block contacts the side of the flat wire II block, and the rotating sleeve and flat wire III block drive the flat wire II block together Rotating around the counterclockwise axis, the angle of rotation of the flat wire II insert v°=y°-u°; when the flat wire II insert rotates counterclockwise, the end of the flat wire II is extended into the flat wire II holding groove Bend in the circumferential direction of the iron core.

Inserts (including flat wire III inserts and flat wire II inserts) have three main states:

The first is the reset state. At this time, the spacing angle between the holding grooves on the insert (flat wire II holding grooves and flat wire III holding grooves) and the flat wire I holding grooves on the rotating sleeve is different from the stator core The groove spacing angle is the same, you can use the side wall of the stagnation groove on the rotating sleeve to circumferentially position the insert;

The second type is the stagnation state. At this time, the rotating sleeve rotates and the insert does not move;

The third state is the twisted state. At this time, the groove wall on the other side of the stagnation groove on the rotating sleeve contacts the insert and drives the insert to rotate together;

In the reset state and the hysteresis state, the holding grooves of the insert block correspond to the flat wires one by one.

Of course, for the driving of the insert, in addition to the illustrated structure, that is, the driving through the rotary sleeve, it is also possible to use an independent power component, such as a servo motor drive, to achieve the above three working states.

As a further improvement to the above-mentioned device for bending the flat wire in the winding of the flat wire motor, there is a step inside the holding section of the rotating sleeve, and the flat wire Ⅲ rotating in axial contact with the step is set inside the holding section The rotation of the flat wire II rotor in axial contact with the flat wire III rotor is set inside the holding section, the flat wire III insert is arranged on the outer periphery of the flat wire III rotor, and the flat wire II insert is arranged on the outer periphery of the flat wire II rotor. Preferably, it further includes a mounting plate fixed on the rotating sleeve. The mounting plate contacts the flat wire II rotor in the axial direction, and the mounting plate and the step jointly define the axial movement of the flat wire III rotor and the flat wire II rotor.

This improvement enables each flat wire II insert to rotate synchronously with the flat wire II rotation, each flat wire III insert to rotate synchronously with the flat wire III rotation, and at the same time, the step limits the axial limit of the flat wire III rotation and the flat wire II rotation This prevents the flat wire III rotor and flat wire II rotor from moving in the axial direction relative to the rotating sleeve, and enables the flat wire III rotor and flat wire II rotor to rotate flexibly in the circumferential direction.

As a further improvement to the above-mentioned device for bending the flat wire in the winding of the flat wire motor, a guide pin is provided on the flat wire III rotating ring, a waist-shaped hole is provided on the flat wire II rotating ring, and the guide pin is moved to the waist-shaped hole Inside.

As a further improvement to the above-mentioned device for bending the flat wire in the winding of the flat wire motor, the rotating sleeve further includes a wall connected to the limit section for extending into the inner hole of the stator core and the wall of the inner hole of the core Contact connection segment.

In short, using the above device for bending flat wires in flat wire motor windings, especially when bending flat wires in flat wire motor windings, one winding layer can be bent at once with different bending angles 1. The bending of the flat wire of the length effectively prevents the flat wire from deforming in the thickness direction of the flat wire, which is beneficial to reducing the skin effect of the bent portion of the flat wire. This patent is to increase the guide sleeve and the limit section so as to be able to bend to avoid skin effect thin wire, prevent the flat wire from deforming in the radial direction of the iron core (that is, deforming in the thickness direction of the flat wire), and ensure that the deformation can only be in the circumferential direction Bending in the direction (that is, deforming in the width direction of the flat wire), the insert can be used to bend the wire at different angles.

BRIEF DESCRIPTION

Figure 1 is a schematic diagram of the structure of the winding layer of the motor winding;

Figure 2 is a schematic diagram of the structure of the winding layer of the motor winding after bending the flat wire;

3 is a disassembly schematic diagram of a device for bending a flat wire in a flat wire motor winding;

4 is a schematic diagram of the structure of the uniform end of the rotary sleeve;

Fig. 5 is a front view of the uniform end rotary sleeve;

Figure 6 is a top view of Figure 5;

7 is a cross-sectional view of FIG. 5;

Figure 8 is a schematic diagram of the structure of the differential end rotary sleeve;

Fig. 9 is a front view of a differential end rotary sleeve;

Figure 10 is a top view of the differential end of the rotary sleeve;

Figure 11 is a side view of the differential end of the rotary sleeve;

FIG. 12 is an enlarged view at A of FIG. 10;

13 is a schematic view of the structure of the flat wire III rotation circle of the specific embodiment 1;

FIG. 14 is a front view of the flat wire III rotation circle of the specific embodiment 1;

15 is a plan view of the flat wire III rotation of the specific embodiment 1;

16 is a cross-sectional view A-A of FIG. 14 (rotated 90°);

17 is a cross-sectional view C-C of FIG. 15;

18 is a partial enlarged view of FIG. 14;

19 is a partial enlarged view of FIG. 15;

FIG. 20 is a schematic view of the structure of the flat wire II rotor in specific embodiment 1;

21 is a front view of a specific example 1 flat wire II rotation;

22 is a plan view of a flat wire II rotating circle of a specific embodiment 1;

FIG. 23 is a side view of the rotation of the flat wire II of the specific embodiment 1 (rotation 90°);

24 is a partial view of the E direction of FIG. 21;

FIG. 25 is a partial view of F in FIG. 21;

FIG. 26 is a C-C sectional view of FIG. 23;

Figure 27 is a schematic diagram of the structure of the mounting plate;

Figure 28 is a front view of the mounting plate;

Figure 29 is a top view of the mounting plate;

Figure 30 is a side view of the mounting plate (rotated 90°);

Figure 31 is a rear view of Figure 28;

Fig. 32 is a schematic structural view of a drum holder;

Figure 33 is a schematic diagram of the structure of the differential end tooling;

Fig. 34 is a schematic structural view of the one-axis cross section of the differential end tooling;

Figure 35 is a schematic view of the installation of uniform end tooling and differential end tooling;

36 is a cross-sectional view A-A of FIG. 35;

Figure 37 is a side view of Figure 35;

Fig. 38 is a side view of the hidden reel base of Fig. 35;

FIG. 39 is a cross-sectional view B-B of FIG. 36 when the differential end rotating sleeve is not rotated;

Fig. 40 is a side view of Fig. 35 when the rotating sleeve at the different end is rotated by 2.5° (hidden drum holder);

FIG. 41 is a cross-sectional view B-B of FIG. 36 when the differential end rotating sleeve rotates 2.5°;

Fig. 42 is a side view of Fig. 35 when the rotating sleeve at the differential end is rotated by 5° (hidden drum holder);

FIG. 43 is a cross-sectional view B-B of FIG. 36 when the differential end rotating sleeve is rotated by 5°;

Fig. 44 is a side view of Fig. 35 when the rotating sleeve at the differential end is rotated by 22.5° (hidden drum holder);

Fig. 45 is a cross-sectional view B-B of Fig. 36 when the differential end rotating sleeve is rotated by 22.5°;

46 is a schematic view of the structure of the flat wire III rotation circle of the specific embodiment 2;

FIG. 47 is a schematic view of the structure of the flat wire II rotating circle of the specific embodiment 2;

Figure 48 is a schematic diagram of disassembly of the differential end of the rotary sleeve;

Fig. 49 is a schematic view of disassembly of a uniform-end rotary sleeve and the like.

detailed description

In the following, with reference to the drawings, the technology will be further described by taking a flat wire used for bending a winding layer in a certain type of motor stator core winding as an example.

As shown in Fig. 1, Fig. 2 and Fig. 3, this patent provides two different devices for bending the flat wire in the winding of the flat wire motor. One is for the one-time bending of the differential end tool 1 of the flat wire B of the differential end CY of one winding layer C in the stator core T, and the other is for the one-time bending of one winding layer C in the stator core T The uniform end tooling 2 of the flat wire B at the uniform end YZ.

The uniform-end tooling 2 includes a flat wire I01 end that is both rotatable about the axis and movable along the axis and is arranged at the end of the stator core T for holding a winding layer C uniform end YZ, applying torque to the flat wire I01 and flattening the flat wire I01 The line I01 applies a thrust to bend the flat wire I01 and bend the flat wire I01 along the circumferential direction of the winding layer C where the flat wire I01 is located. The uniform end turn sleeve 21 is sleeved on the uniform end turn sleeve 21 to prevent the flat wire B is the uniform end guide sleeve 22 that deforms radially outward along the stator core T.

The differential end tooling 1 includes a flat wire I01 end that is both rotatable about the axis and movable along the axis and is provided at the T end of the stator core for holding the differential end CY, applying torque to the flat wire I01 and applying thrust to the flat wire I01 By bending the flat wire I01 and bending the flat wire I01 along the circumferential direction of the winding layer C where the flat wire B is located, the differential end turn sleeve 11 is slidably arranged in a stagnation groove on the differential end turn sleeve 11 for clamping After holding the flat wire Ⅲ03, the flat wire Ⅲ insert 131 that rotates synchronously with the differential end rotary sleeve 11 after stagnation at a fixed angle relative to the differential end rotary sleeve 11 is slidably set in the stagnation groove on the differential end rotary sleeve 11. After holding the flat wire Ⅱ02, the flat wire Ⅱ insert 141 synchronously rotates with the flat wire Ⅲ insert 131 after stagnation at a fixed angle relative to the flat wire Ⅲ insert 131. The flat end wire B guides the differential end deformed radially outward along the stator core T.

This type of motor stator core winding has 48 flat wires B in one winding layer; for the uniform end, 48 flat wires B are all flat wires I01; for the difference end, there are 36 flat wires I01, 6 flat wires III03 And 6 flat wires II02.

Designed flat wire I01 bending angle D ₁ = 22.5° (clockwise), flat wire III03 bending angle D ₃ = 22.5°-2.5° = 20° (clockwise), flat wire II02 bending angle D ₂ = 22.5 °-5°=17.5° (clockwise).

Refer also to Figures 4-7, regarding the uniform end tooling 2:

The uniform-end rotating sleeve 21 is, in order from the inside to the outside, a connecting section 211 for rotationally connecting with the inner hole of the stator core T, a limiting section 212 for preventing the flat wire B from deforming radially inward along the stator core T, for The holding flat wire I01 draws a uniform holding section 213 that bends the flat wire B toward the circumferential direction.

The connecting section 211 centers the uniform-end rotary sleeve 21 in the stator core T, and at the same time, the uniform-end rotary sleeve 21 can move axially relative to the inner hole of the stator core T and rotate around the axis.

The outer diameter of the limiting section 212 is the inner diameter of the winding layer C, and its length is not greater than the projected length of the bent section B ₁ of the bent flat wire B in the direction of the stator core T axis.

A flat wire I holding groove 2131 corresponding to the flat wire I01 in the winding layer C is provided on the outer periphery of the uniform holding section 213, and the flat wire I holding groove 2131 is radially The depth of the notch is the same as the thickness h of the flat wire B. The difference between the width of the flat wire I holding groove 2131 and the width k of the flat wire B is 0mm-0.4mm (in this embodiment, the width of the flat wire I holding groove 2131 is selected The difference between the width k of the flat wire B is 0 mm, that is, the width of the holding groove 2131 of the flat wire I is equal to the width k of the flat wire B); the outer diameter of the uniform holding section 213 is twice the outer diameter of the limiting section 212 The sum of the thickness h of the flat wire B.

The uniform end guide sleeve 22 is a circular ring structure, and its inner diameter is equal to the outer diameter of the uniform holding section 213, and the length of the uniform end guide sleeve 22 is the sum of the length of the uniform holding section 213 and the length of the limiting section 212.

The flat wire I holding groove 2131 is rounded 2132, and the flat wire I holding groove 2131 is provided with a limiting boss 2133. The slot 2131 of the flat wire I has the same height in the axial direction. In this example, there are 48 flat wire I holding slots 2131.

See also Figures 8-32, regarding the differential end tooling 1:

From the inside to the outside, the differential end turning sleeve 11 is a connecting section 111 for rotatingly connecting with the inner hole of the stator core T, a limit section 112 for preventing the flat wire B from deforming radially inward along the stator core T, and The clamping flat wire I01 pulls the flat wire B to bend in the circumferential direction by a differential clamping section 113.

The connecting section 111 centers the differential-end rotary sleeve 11 in the stator core T, and at the same time, the differential-end rotary sleeve 11 can move axially relative to the inner hole of the stator core T and rotate around the axis.

The outer diameter of the limiting section 112 is the inner diameter of the winding layer C, and its length is not greater than the projected length of the bent section B ₁ of the bent flat wire I01 in the direction of the T axis of the stator core.

A flat wire I holding groove 1131 corresponding to the flat wire I01 in the winding layer C is provided in the circumferential direction of the differential holding section 113 in a one-to-one manner. For reliable holding and uniform force application, the flat wire I holding groove 1131 The depth of the notch in the radial direction is equal to the thickness h of the flat wire B. The difference between the width of the flat wire I holding groove 1131 and the width k of the flat wire B is 0mm-0.4mm (in this embodiment, the flat wire I holding groove is selected The difference between the width of 1131 and the width k of the flat wire B is 0mm, that is, the width of the flat wire I holding groove 1131 is equal to the width k of the flat wire B); the outer diameter of the differential holding section 113 is the outer diameter of the limiting section 112 The sum of twice the thickness of the flat wire B.

The inner diameter of the differential end guide sleeve 12 is equal to the outer diameter of the differential clamping section 113, and its inner end is aligned with the limiting section 112 of the limiting section 112.

An axial stagnation slot 1135 is recessed on the outer periphery of the outer end of the differential holding section 113. The stagnation slot 1135 has a fan-shaped cross section, and the flat wire III insert 131 and the flat wire II insert 141 having a fan-shaped cross section are slidably arranged at In the stagnation slot 1135.

A flat wire III holding groove 132 corresponding to the flat wire III03 in the winding layer C for holding the flat wire III03 and pulling the flat wire III03 to bend in the circumferential direction is formed on the flat wire III insert 131 The wire III holding groove 132 and the flat wire I holding groove 1131 are on the same circumference.

In the axial direction, the notch of the flat wire III holding groove 132 protrudes from the notch of the flat wire I holding groove 1131 by 2mm-3mm (in this example, the notch of the flat wire III holding groove 132 is higher than the flat wire (The slot of the I-holding slot 1131 is 2.5mm), the bottom of the flat wire III holding slot 132 protrudes from the bottom of the flat-line I holding slot 1131 by 5mm-7mm (in this example, the flat wire III holding slot 132 is used) The groove bottom protrudes from the groove bottom of the flat wire I holding groove 1131 by 6 mm).

The center angle between the adjacent wall of the stagnation groove 1135 and the side of the flat line III insert 131 is the designed flat line III stagnation angle. In this example, the designed flat line III lag angle is 2.5°.

The flat line III insert block 131 and the flat line II insert block 141 are alternately arranged.

A flat wire II holding groove 142 corresponding to the flat wire II02 in the winding layer C for holding the flat wire II02 and pulling the flat wire II02 to bend in the circumferential direction is formed on the flat wire II insert 141, The flat wire II holding groove 142 and the flat wire I holding groove 1131 are on the same circumference. In the axial direction, the notch of the flat wire II holding groove 142 protrudes from the notch of the flat wire I holding groove 1131 by 4mm-5mm (in this example, the notch of the flat wire II holding groove 142 protrudes from the flat wire (The slot opening of the I-holding slot 1131 is 4.5 mm), and the bottom of the flat-line II holding slot 142 is the same height as the bottom of the flat-line I holding slot 1131.

The center angle between the side of the adjacent flat wire II insert 141 and the side of the flat wire III insert 131 is the difference between the designed flat wire II hysteresis angle and the flat wire III hysteresis angle. In this example, the designed flat wire II lag angle is 5°, then the difference between the flat wire II lag angle and the flat wire Ⅱ lag angle is 5°-2.5°=2.5°; the flat wire I holding groove 1131 There are 36, and the flat wire III holding groove 132 and the flat wire II holding groove 142 each have six.

The specific implementation manner that the flat wire III insert block 131 and the flat wire II insert block 141 are movably arranged on the differential end turning sleeve 11 is as follows:

There is a step 1134 inside the differential holding section 113, a stagnation groove 1135 is recessed on the outer periphery of the differential holding section 113, a flat wire III insert 131 is protruded on the outer periphery of the flat wire III turning ring 13 and a periphery of the flat wire II turning ring 14 The flat wire II insert 141 is provided, the flat wire III rotating ring 13 and the flat wire II rotating ring 14 are rotated and arranged inside the differential holding section 113, the flat wire II rotating ring 14 is rotatingly arranged outside the flat wire III rotating ring 13, and the flat wire III rotating ring 13 is rotated The inside is in contact with the step 1134. The flat wire III insert 131 protrudes axially outward from the flat wire III rotor 13, and the flat wire II insert 141 protrudes axially inward from the flat wire II rotor 14.

There are two ways to connect the flat wire III insert 131 to the flat wire III rotor 13:

Specific Embodiment 1: The flat wire III insert 131 and the flat wire III rotating ring 13 are an integrated structure;

Specific Embodiment 2 (see FIG. 46): an insertion hole 135 is formed in the flat wire III rotating ring 13, an insertion handle 1311 is protruded on the flat wire III insertion block 131, and the insertion handle 1311 and the insertion hole 135 are interference fitly connected.

There are also two ways to connect the flat wire II insert 141 to the flat wire II rotor 14:

Specific Embodiment 1: The flat wire II insert 141 and the flat wire II rotating ring 14 are of an integrated structure;

Specific embodiment 2 (see FIG. 47): an insertion hole 145 is formed on the flat wire II rotating ring 14, an insertion handle 1411 is protruded on the flat wire II insertion block 141, and the insertion handle 1411 and the insertion hole 145 are connected with interference fit.

In a specific application, the connection method of the flat wire II insert block 141 and the flat wire II rotating ring 14 and the connection method of the flat wire III insert block 131 and the flat wire III rotating ring 13 can be freely combined. In this case, the flat wire II insert 141 and the flat wire II rotating ring 14, the flat wire III insert 131 and the flat wire III rotating ring 13 are all integrated.

The pin holes 133 are evenly distributed along the circumferential direction on the flat wire III rotating ring 13, the guide pins 134 are arranged in the pin holes 133, and the waist holes 143 are evenly distributed along the circumferential direction on the flat wire II rotating ring 14, and the guide pins 134 are moved and arranged in the waist hole 143 .

A mounting plate 15 is fixedly connected to the outer end of the rotating sleeve 11 at the differential end. The installation plate 15 with the flange structure as the main body can ensure that the flat wire III rotating ring 13 and the flat wire II rotating ring 14 can rotate flexibly in the differential end rotating sleeve 11, and the flat wire III rotating ring 13 and the flat wire II rotating ring can also be axially Positioning.

The differential end tooling 1 further includes a rotating drum base 17 fixedly connected to the outer end of the differential end rotating sleeve 11 and located outside the mounting plate 15. The drum base 17 is provided, on the one hand, the axial limit of the differential end guide sleeve 12 that is fitted on the differential end rotary sleeve 11 is provided, and on the other hand, the drum base 17 provides an installation basis for the differential end tooling 1 to be installed on the torsion machine and passes The rotating drum base 17 applies an axial thrust force to the differential end tool 1 so that the differential end tool 1 moves axially in the stator core T.

In the flat wire I holding groove 1131, the top of the flat wire III insert block 131 and the top of the flat wire II insert block 141 are provided with a holding groove serial number 18, which corresponds to the flat wire serial number.

In the flat wire I holding groove 1131, the flat wire III holding groove 132 and the flat wire II holding groove 142 are provided with rounding 19, and in the flat wire I holding groove 1131, the flat wire III holding groove 132 and flat A limit boss 20 is provided at the bottom of the groove of the line II holding groove 142.

A mounting groove 144 is formed on the flat wire II rotating ring 14 and a groove 21 is formed on the mounting plate 15, the differential end guide sleeve 12 and the drum base 17, and the size of the center angle of the groove 21 is to ensure that the return block 16 does not swing Contact with the groove 21. A rod-shaped return block 16 indicating the rotation angle of the flat wire II rotating ring 14 is inserted into the mounting groove 144 through the groove 21, and the return block 16 is fixedly connected to the flat wire II rotating ring using screws (not shown) 14 on.

In the following, in conjunction with the drawings, the flat wire in a winding layer of the stator winding of a certain type of motor mentioned above is taken as an example with the help of a torsion machine, and the use method of the device for bending the flat wire in the flat wire motor winding is described in detail:

Referring to FIGS. 35-45, the process of bending the flat wire in one winding layer using the above-mentioned device for bending a flat wire in a winding of a flat wire motor.

1. Position the threaded stator core T on the torsion machine;

2. Use the uniform end tooling 2 to bend the flat wire I01 of the uniform end YZ:

1). Connect the unison end sleeve 21 to the stator core T: center the unison end sleeve 21 in the stator core T through the connecting section 211;

2). At the same end, the sleeve 21 holds the end of the flat wire I01: insert the flat wire I01 into the flat wire I holding groove 2131 one by one, so that the end of the flat wire I01 is in reliable contact with the limit boss 2133;

3). Set the uniform end guide sleeve 22: the uniform end guide sleeve 22 is set from the outer end of the uniform end turn sleeve 21 to the uniform end guide sleeve 22 and the uniform end turn sleeve 21;

4). According to the design bending direction (clockwise), twist the uniform-end rotary sleeve 21 and apply an axial thrust force to the uniform-end rotary sleeve 21 to bend the flat wire I01 to the design bending angle (22.5°), and the uniform-end rotary sleeve 21 It retracts into the stator core T and prevents the flat wire I01 from deforming radially inward, and the uniform end guide sleeve 22 prevents the flat wire I01 from deforming radially outward.

3. Use the differential end tooling 1 to bend the flat wire B of the differential end CY:

1). Connect the differential sleeve 11 to the stator core T: center the differential sleeve 11 in the stator core T through the connecting section 111;

2). Installation and installation plate: The flat wire III rotating ring 13 and the flat wire II rotating ring 14 are successively arranged in the differential end rotating sleeve 11, and the mounting plate 15 fixed with the return block 16 and the differential end rotating sleeve 11 are fixedly connected:

3), the differential end turn sleeve 11 holds the end of the flat wire I01; the flat wire III turns 13 holds the end of the flat wire III03; the flat wire II turns 14 holds the end of the flat wire II02; according to the slot number 18 and flat According to the principle of line number 04, insert the flat wire I01 into the flat wire I holding slot 1131 one by one, insert the flat wire III03 into the flat wire III holding slot 132 one by one, and insert the flat wire II02 one by one Correspondingly insert into the flat wire II holding groove 142, so that the end of the flat wire I01 is in reliable contact with the limit boss 20;

4), set the differential end guide sleeve 12: the differential end guide sleeve 12 is set from the outer end of the differential end turn sleeve 11 to the inner end of the differential end guide sleeve 12 and the inner end of the limit section 112;

5). Install the rotating drum base 17: use screws to fix the rotating drum base 17 and the differential end rotating sleeve 11;

6). Apply axial thrust and (clockwise) circumferential torque on the drum base 17:

a). The rotating drum base 17 rotates to drive the differential end rotating sleeve 11 to rotate. The bending angle to the flat wire I01 is the set angle (2.5°) of the flat wire III rotating ring 13 relative to the differential end rotating sleeve 11 stagnation, the differential end The limit section 112 of the rotating sleeve 11 prevents the flat wire I01 from deforming radially inward. At this time, the differential end rotating sleeve 11 retracts into the stator core T, and the flat wire III rotating ring 13 is about to rotate;

b). The differential end rotating sleeve 11 drives the flat wire III rotating ring 13 to rotate, and the bending angle to the flat wire I01 is the setting angle (2.5°) of the flat wire III rotating ring 13 relative to the differential end rotating sleeve 11 and the flat wire II The sum of the lagging set angle (2.5°) of the rotating ring 14 relative to the flat line III rotating ring 13 (2.5°+2.5°=5°), the bending angle of the flat line III03 is the flat line II rotating ring 14 relative to the flat line III rotating ring 13 Hysteresis setting angle (2.5°), the limit section 112 of the differential end sleeve 11 prevents radial inward deformation of the flat wire I01 and flat wire III03, and the differential end guide sleeve 12 prevents radial of the flat wire I01 and flat wire III03 Deformed outwards, at this time, the differential end of the rotating sleeve continues to retract into the 11 stator core T, and the flat wire II rotor 14 is about to rotate;

c). The differential end rotating sleeve 11 drives the flat wire III rotating ring 13 and the flat wire II rotating ring 14 to the bending angle of the flat wire I01 to the set angle (bending angle D ₁ = 22.5°), the differential end rotating sleeve 11 The limiting section 112 prevents the flat wire B from deforming radially inward, and the differential end guide sleeve 12 prevents the flat wire B from deforming radially outward. At this time, the differential end turn sleeve 11 continues to retract into the stator core T to the differential end The connecting section 111 of the rotating sleeve 11 abuts the stator core T, and the bending angle of the flat wire III03 is the bending angle of the flat wire I01 and the angle of the flat wire III rotating ring 13 relative to the differential end rotating sleeve 11 The difference (bending angle D ₃ = 22.5°-2.5°=20°), the bending angle of the flat wire II02 is the bending angle of the flat wire III01 and the flat wire II rotating ring 14 is delayed relative to the flat wire III rotating ring 13 Difference of fixed angle (bending angle D ₂ =20°-2.5°=17.5°).

The beneficial effect of the technology is that the above device for bending a flat wire in a flat wire motor winding is used to bend a flat wire, especially when bending a flat wire in a flat wire motor winding, one winding layer can be bent at a time The flat wires with different bending angles and bending lengths can effectively prevent the flat wires from being deformed in the direction of the thickness of the flat wires, which is beneficial to reduce the skin effect of the bent portions of the flat wires.

Claims

A device for bending a flat wire in a winding of a flat wire motor includes a rotating sleeve, a driving device that drives the axial movement of the rotating sleeve and rotation around the axis, and is characterized in that a flat wire I is provided on the outer periphery of the rotating sleeve Slots, each flat wire I holding slot is opposed to the end of a part or all of the flat wire passing through the same circumference of the iron core of the flat wire motor winding in the axial direction; it is axially opposed to the flat wire I holding slot The opposite flat wire is called flat wire I; when the rotating sleeve moves toward the end of the core in the axial direction, the end of the flat wire I can extend into the opposing flat wire I holding groove; when the rotating sleeve rotates, the The flat wire I extending into the holding groove of the flat wire I is bent in the circumferential direction of the core; on the same circumference, the outer circumference of the flat wire surrounds the guide sleeve, and the outer circumference of the guide sleeve is on the same circumference as the flat wire The outer sides in the radial direction are contacted to prevent the flat wires from being deformed radially outward in the stator core when they are bent. The limit section is connected with the clamping section, and the outer circumference of the limit section is in contact with the inner side of the flat wire in the radial direction on the same circumference to prevent the flat wire from bending radially inward of the stator core when bending Deformed.
The device for bending a flat wire in a flat wire motor winding according to claim 1, wherein each flat wire I holding groove is connected to an end of a part of the flat wire passing through the iron core in the flat wire motor winding In the axial direction, the flat wires except the flat wire I are called residual flat wires; the portion of the sleeve with the flat wire I holding groove is called the holding section; the holding section is along the circumferential direction There is a stagnation slot in the direction, and a flat wire III block is slid in the slewing slot in the circumferential direction of the sleeve; from the wall of the stagnation slot to the center of the side of the flat line III block opposite to it in the circumferential direction The angle size is x°; the outer side of the flat wire III block is provided with flat wire III holding grooves, and each flat wire III holding groove is opposed to some or all of the ends of the remaining flat wires in the axial direction; and The remaining flat wire of the flat wire III holding groove axially opposite is called the flat wire III; when the rotating sleeve moves toward the end of the iron core in the axial direction, the end of the flat wire III can extend into the opposite flat wire III holding groove Inner; when the rotation angle of the rotary sleeve is z°≤x°, the rotary sleeve rotates in the circumferential direction relative to the flat line III block, the flat line III block does not rotate; when the rotary sleeve rotation angle z°>x° The groove wall is in contact with the side of the flat line III block. The rotating sleeve drives the flat line III block to rotate around the axis. The angle of rotation of the flat line III block is y°=z°-x°; when the flat line III block rotates So that the flat wire III extending into the holding groove of the flat wire III is bent in the circumferential direction of the iron core.
The device for bending a flat wire in a flat wire motor winding according to claim 2, wherein each flat wire III holding groove is opposed to the ends of some remaining flat wires in the axial direction one by one, except The remaining flat wire outside flat wire III is called flat wire II; a flat wire II insert slides in a stagnation groove in the circumferential direction of the rotary sleeve; flat wire III insert and flat wire II insert are located in a lag In the chute; the center angle between the side of the flat wire III block to the side of the flat wire II block opposite to it in the circumferential direction is u°; the outer side of the flat wire II block is provided with a flat wire II holding groove, Each flat wire II holding groove is opposed to the end of the flat wire II in the axial direction one by one; when the rotating sleeve moves toward the end of the core in the axial direction, the end of the flat wire II can extend into the opposite flat wire II In the holding groove; when the rotation angle of the flat wire III block is y°≤u°, the rotary sleeve and the flat wire III block rotate relative to the flat wire II block, and the flat wire II block does not rotate; when flat When the rotation angle of the line III block is y°>u°, the side of the flat line III block is in contact with the side of the flat line II block. The rotating sleeve and the flat line III block drive the flat line II block to rotate around the axis together, the flat line II The angle of rotation of the insert block v°=y°-u°; when the insert block of the flat wire II rotates, the flat wire II extending into the holding groove of the flat wire II is bent in the circumferential direction of the iron core.
The device for bending a flat wire in a flat wire motor winding according to claim 1, wherein the rotating sleeve further comprises a limit section connected to the inner hole of the stator core and connected with the iron The connection section where the wall of the hole in the core contacts.