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WO2021208514A1 - 一种扁线电机定子平面发卡成型装置 - Google Patents

一种扁线电机定子平面发卡成型装置 Download PDF

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Publication number
WO2021208514A1
WO2021208514A1 PCT/CN2020/141448 CN2020141448W WO2021208514A1 WO 2021208514 A1 WO2021208514 A1 WO 2021208514A1 CN 2020141448 W CN2020141448 W CN 2020141448W WO 2021208514 A1 WO2021208514 A1 WO 2021208514A1
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WO
WIPO (PCT)
Prior art keywords
indenter
forming
flat wire
hairpin
motor stator
Prior art date
Application number
PCT/CN2020/141448
Other languages
English (en)
French (fr)
Inventor
刘蕾
夏善伟
汪波
胡冬宝
Original Assignee
安徽巨一科技股份有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 安徽巨一科技股份有限公司 filed Critical 安徽巨一科技股份有限公司
Priority to EP20931392.3A priority Critical patent/EP4024683A4/en
Publication of WO2021208514A1 publication Critical patent/WO2021208514A1/zh

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
    • H02K15/0414—Windings consisting of separate elements, e.g. bars, hairpins, segments, half coils
    • H02K15/0421—Windings consisting of separate elements, e.g. bars, hairpins, segments, half coils consisting of single conductors, e.g. hairpins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21F—WORKING OR PROCESSING OF METAL WIRE
    • B21F1/00—Bending wire other than coiling; Straightening wire
    • B21F1/004—Bending wire other than coiling; Straightening wire by means of press-type tooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21F—WORKING OR PROCESSING OF METAL WIRE
    • B21F45/00—Wire-working in the manufacture of other particular articles

Definitions

  • the invention relates to the technical field of flat wire forming of a motor, in particular to a flat wire motor stator plane hairpin forming device.
  • flat wire windings Compared with ordinary windings, flat wire windings have the characteristics of light weight, high efficiency, and low noise under high pressure under the same volume; from a technical point of view, under the same size, it can pass more current and adapt to higher frequencies. , To obtain a higher quality factor, but the flat wire winding is not widely used in the domestic market due to its greater difficulty in assembly.
  • the number of hairpin layers needs to be increased accordingly, so there may be multiple layers of hairpins in a stator. Since the hairpins are arranged along the radial direction of the stator at a time, the size of each layer of hairpins is different.
  • the issuance cards are arranged in a limited space. In order to avoid interference between the issuance cards, the card issuance needs to have corresponding avoidance, which leads to the complicated shape of the card issuance.
  • some flat wire forming devices are stamping equipment. Although the flat wire can be stamped into a set shape, the paint film of the flat wire is relatively damaged, which will shorten the life of the motor.
  • the purpose of the present invention is to provide a flat wire motor stator plane hairpin forming device, which is suitable for forming flat wire hairpins of various shapes and sizes, and meets the requirements of high versatility.
  • the present invention proposes a flat wire motor stator plane hairpin forming device, which includes two forming mechanisms arranged symmetrically, the forming mechanism includes a forming mold assembly and a forming drive mechanism, and two forming mold assemblies arranged symmetrically. Including: a pair of indenters three in the center, a pair of indenters two on the outside of the pair of indenters, and a pair of indenters one on the outside of the pair of indenters two, wherein the top surfaces of all the indenters are provided for placement A forming groove for placing straight strips of flat wires.
  • the forming drive mechanism is used to drive the forming mold assembly to rotate around the center of rotation to bend the middle of the flat wire, and also to drive the second indenter to move relative to the third indenter to bend the middle bending section of the flat wire
  • the length is adjusted and used to drive the first indenter to deflect relative to the second indenter to bend the long straight legs of the flat wire.
  • the forming drive mechanism includes a base, a lower actuator, a circular arc guide rail, a circular arc guide rail 2, a lower guide block, a rotating plate, and a cam follower 1.
  • the forming drive mechanism is used to drive the rotation The plate rotates along the first arc guide rail and the second arc guide rail.
  • the forming drive mechanism further includes a front actuator, a front connecting piece arranged on the upper side of the front actuator, and a transition plate
  • the forming drive mechanism further includes a rear actuator, a rear connecting piece arranged on the upper side of the rear actuator, The cam fork, the second cam follower, and the rotating block, wherein the rotating shaft of the rotating block is fixedly connected to the transition plate.
  • the first indenter is fixedly connected to the rotating block
  • the second indenter is fixedly connected to the transition plate
  • the rotating plate is fixedly connected to the third indenter
  • the rear actuator is used to drive the rotating block to rotate to drive
  • the first indenter is deflected relative to the second indenter; when the front actuator and the rear actuator move synchronously, it is used to drive the second and first indenter to translate relative to the third indenter as a whole.
  • a pressing plate is provided between the first arc guide rail and the base.
  • the lower actuator is located in the gap between the first circular arc guide rail and the second circular arc guide rail.
  • the rotating plate is provided with a first sliding block that cooperates with a circular arc guide rail one and a second sliding block that cooperates with the circular arc guide rail two, wherein the position of the first sliding block is offset from the second sliding block.
  • the radial direction of the slider is provided with a first sliding block that cooperates with a circular arc guide rail one and a second sliding block that cooperates with the circular arc guide rail two, wherein the position of the first sliding block is offset from the second sliding block.
  • the forming device is used for bending flat U-shaped symmetrical card issuance and asymmetrical card issuance, that is, the card issuance includes U-shaped symmetrical card issuance and U-shaped asymmetrical card issuance.
  • a thread-removing rod is slidably provided in the second pressing head, and the top of the thread-removing rod can protrude into the forming groove.
  • a top line cylinder is provided on the rotating plate, and a top line transition rod is provided between the top line cylinder and the top line rod.
  • a spring one is provided between the top line rod and the second pressure head, and the bottom of the top line rod is provided with a snap spring one.
  • top line transition rod is arranged in the rotating shaft connecting the transition plate and the rotating block, and the top line transition rod is provided with two springs, and the bottom of the top line transition rod is provided with a circlip two.
  • the present invention has the following beneficial effects:
  • the flat wire motor stator plane hairpin forming device of the present invention controls the movement of the pressure head through different actuator displacements.
  • the shape on the hairpin plane can be controlled by the displacement of the electric actuator. It has strong adaptability and High versatility, high work efficiency, use limited models of molds to complete the forming of different shapes of hairpins, reduce design costs and processing costs, and improve economic benefits;
  • the formed flat wire hairpin can be taken out from the forming groove in the indenter to realize automation, improve work efficiency and reduce manpower.
  • the flat wire motor stator plane hairpin forming device of the present invention realizes the arc-forming shape of the U-shaped part of the hairpin through simple bending, which has less damage to the flat wire compared to stamping and forming; at the same time, the overall structure arrangement of the present invention It is compact, coordinated, and does not cause interference.
  • Figure 1 is a perspective view of the flat wire motor stator flat hairpin forming device of the present invention
  • FIG. 2 is a perspective view of the partial structure of the flat wire motor stator flat hairpin forming device of the present invention
  • Figure 3 is a top view of the flat wire motor stator flat hairpin forming device of the present invention.
  • Figure 4 is a front view of the flat wire motor stator flat hairpin forming device of the present invention.
  • FIG. 5 is a cross-sectional view of a partial mechanism of the flat wire motor stator flat hairpin forming device of the present invention.
  • FIG. 6 is a top view of the partial mechanism of the flat wire motor stator flat hairpin forming device of the present invention.
  • FIG. 7 is a schematic diagram of the straight line state of the flat wire hairpin before forming in the present invention.
  • Fig. 8 is a schematic diagram of the shape and structure of a flat wire hairpin that can be formed by using the forming device of the present invention.
  • FIGS 1 to 8 show some embodiments according to the present invention.
  • a flat wire motor stator plane hairpin forming device includes two forming mechanisms arranged symmetrically and symmetrically, and the mechanical structures of the two forming mechanisms are completely the same.
  • the forming mechanism includes a forming mold assembly And forming drive mechanism.
  • the two forming mold components arranged symmetrically include: a pair of indenters 49 arranged in the center, and a pair of indenters 47 located outside the pair of indenters 49. , And a pair of indenters 45 outside the pair of indenters 47, wherein the top surfaces of all the indenters are provided with a forming groove for placing straight strips of flat wires.
  • the forming drive mechanism includes a forming drive mechanism for driving the forming mold assembly to rotate around the center of rotation to bend the middle of the flat wire, and also for driving the indenter two 47 to translate relative to the indenter three 49 to align the middle bending section of the flat wire.
  • the bending length is adjusted, and it is also used to drive the indenter 45 to deflect relative to the indenter 47 to bend the long straight legs of the flat wire.
  • the forming driving mechanism includes a base 1, and a lower actuator 3 installed on the upper end of the base 1, a circular arc guide 5, a circular arc guide 9, a lower guide block 11, a rotating plate 27, and a cam follower 51 ,
  • the rotating plate 27 is installed on the arc guide rail one 5 and the arc guide rail two 9, and is slidably connected with the arc guide rail one 5 and the arc guide rail two 9, the lower guide block 11 and the slider on the lower actuator 3
  • the lower guide block 11 is connected to the rotating plate 27 through a cam follower 51, and the rotating plate 27 is provided with an indenter 49.
  • the lower actuator 3 is located in the gap between the circular arc guide rail one 5 and the circular arc guide rail two 9, and at the same time, the rotating plate 27 is provided with a first sliding block that cooperates with the circular arc guide rail one 5.
  • the second sliding block that cooperates with the second circular arc guide rail 9, wherein the position of the first sliding block is offset from the radial direction of the second sliding block, that is, the connection formed by the first sliding block and the arc center where it is located Line 1, the line two formed by the second sliding block and the center of the arc. Line one and line two intersect and are not parallel; make the lower actuator 3 drive the rotating plate 27 on the arc guide rail one 5 and the arc guide rail two. 9 moves more smoothly and smoothly.
  • the lower actuator 3 can drive the lower guide block 11 to move linearly, and then drive the rotating plate 27 along the cam follower 51 through the cam follower 51
  • the arc guide rail 5 and the arc guide rail 2 9 move, so that the rotating plate 27 and the indenter 3 49 rotate above the base 1.
  • the three indenters 49 on the forming mechanism and the three indenters 49 on the right forming mechanism are both provided with a forming groove at the upper end. Due to the relative rotation between the two indenters 49, the flattened in the forming groove can be aligned. The wire hairpin is folded to make a bent part 61 of the flat wire hairpin (as shown in Fig. 8).
  • the upper end of the rotating plate 27 is fixedly installed with a front actuator 29 and a rear actuator 31, the front connector 33 is installed on the slider of the front actuator 29, and the transition plate 43 is fixedly installed on the front connector.
  • the rotating block 41 is installed on the transition plate 43, and the rotating block 41 is rotatably connected with the transition plate 43 through a rotating shaft.
  • the rear connecting piece 35 is installed on the sliding block of the rear actuator 31, the cam fork 39 is fixed on the upper end of the rear connecting piece 35, the second cam follower 37 is fixedly connected to the rotating block 41, and the upper end of the second cam follower 37 is located on the cam In the waist-shaped groove of the shift fork 39.
  • indenter one 45 is fixedly installed on the upper end of the front part of the rotating block 41
  • indenter two 47 is fixedly installed on the transition plate 43
  • indenter one 45 and indenter two 47 are provided with forming grooves, and two forming The grooves are collinear, and the flat wire that needs to be formed can be placed.
  • the rear actuator 31 drives the rear connecting piece 35 and the cam fork 39 to move linearly to the outside, and the cam follower 37 moves with the cam fork 39 to drive the rotating block 41 rotates around the shaft between the two on the transition plate 43, and the rotation of the rotating block 41 can drive the indenter 45 to rotate together; at the same time, because the front actuator 29 does not work, the indenter two 47 and the indenter three 49 are opposed to each other. The location remains the same.
  • the flat wire hairpin 60 can be bent and formed, so that the flat wire hairpin 60 produces a second bending portion 62 and a third bending portion 63 (as shown in FIG. 8).
  • the flat wire can be folded into a flat U-shaped flat wire having a bent portion 61, a bent portion 62, and a bent portion 63 through the above structure.
  • Issuing cards; among them, the U-shaped flat-line issuing cards include a symmetrical flat U-shaped issuing card and an asymmetrical flat U-shaped issuing card.
  • the front actuator 29 can also work simultaneously with the rear actuator 31.
  • the front actuator 29 can drive the front connecting piece 33, and the transition plate 43, the rotating block 41, the indenter 45, and the front connecting piece 33 mounted on the front connecting piece 33.
  • the second head 47 and the second cam follower 37 move outward, while the rear actuator can drive the rear connector 35 and the cam fork 39 to move outward.
  • the front actuator 29 drives the front connecting piece 33 and the transition plate 43 to move, that is, the distance between the indenter two 47 and the indenter three 49 changes, so that the contact surface between the indenter one 45 and the indenter two 47 is two
  • the distance between the contact surface of the indenter three 49 reaches the set value, so that this distance is consistent with the distance between the bent portion two 62 and the bent portion 61 of the flat wire hairpin that needs to be formed.
  • the indenters 45 on the two forming mechanisms are rotated, and then the flat wire hairpins are bent and formed, so that the flat wire hairpins produce bending part two 62 and bending part three. 63. Therefore, the spatial shape of the hairpin can be controlled by the displacement of the electric actuator, and flat wire hairpins of different sizes can be bent.
  • the top line transition rod 15 is provided in the rotating shaft connecting the transition plate 43 and the rotating block 41, and the top line transition rod 15 is sleeved with two springs 17, and the top line transition A second circlip 19 is provided at the bottom of the rod 15, and the second circlip 19 is used to fix the second spring 17.
  • the second spring 17 is in a compressed state, which can force the top line transition rod 15 to move down the axis in the transition plate 43.
  • the second indenter 47 is provided with a top line rod 21 that linearly slides in the vertical direction, and the top of the top line rod 21 is located in the forming groove at the upper end of the second indenter 47 when the top line rod 21 moves upward.
  • a spring 23 is sleeved in the middle and lower part of the top line rod 21, a circlip 25 is provided at the bottom of the top line rod 21, and the circlip 25 is used to fix the spring 23.
  • the spring one 23 is in a compressed state, which can force the top line rod 21 to move down the axis in the second press head 47.
  • the top line rod 21 is located above the top line transition rod 15, the top line cylinder 13 is provided on the lower side of the top line rod 21, and the top line cylinder 13 is fixedly installed on the rotating plate 27.
  • top line cylinder 13 When the top line cylinder 13 moves axially, it can withstand the top line transition rod 15 and move upward axially, and then push the top line rod 21 to move upward axially in the indenter two 47, so that the top of the top line rod 21 protrudes from the pressure.
  • the arc guide rail 5 is connected to the base 1 and pressed by the pressing plate 7, so that the arc guide rail 5 is installed more stably, and the rotating plate 27 is on the arc guide rail 5. Sliding is smoother.
  • the forming grooves of indenter one 45, indenter two 47, and indenter three 49 on the left side forming mechanism and the indenter one 45, indenter two 47, and indenter on the right side forming mechanism The forming grooves of the first three 49 are collinear, and then the straight flat wire hairpin is placed in a straight forming groove formed by the indenter one 45, the indenter two 47, and the indenter three 49.
  • the linear motion of the lower actuator 3 is converted into In order to rotate the rotating plate 27, the indenter one 45, the indenter two 47, and the indenter three 49 are rotated along with the rotating plate 27.
  • the three indenter 49 on the left forming mechanism and the three indenter 49 on the right forming mechanism rotate relative to each other to fold the flat wire hairpin, so that the flat wire hairpin generates a bent portion 61.
  • the rear actuator 31 drives the rear connecting piece 35 and the cam fork 39 to move horizontally and linearly, and the second cam follower 37 With the movement of the cam fork 39, the rotating block 41 is driven to rotate on the transition plate 43 around the two rotating shafts.
  • the rotating block 41 then drives the indenter one 45 to rotate.
  • the front actuator 29 does not work, causing the indenter two 47 to rotate.
  • the position of the indenter three 49 remains unchanged.
  • the flat wire hairpin By rotating the indenter one 45 on the left forming mechanism relative to the indenter two 47, the flat wire hairpin can be bent and formed, so that the flat wire hairpin produces a bent portion 62; through the indenter one on the right forming mechanism The 45 rotates relative to the indenter two 47, which can bend the flat wire hairpin to form a bending part 63 of the flat wire hairpin.
  • the top line transition rod 15 can be pushed upward and axially, and then the top line rod 21 can be pushed upward in the indenter two 47.
  • Axial movement causes the top of the wire rod 21 to protrude from the bottom of the forming groove on the second indenter 47, thereby pushing the formed flat wire hairpin out of the forming groove on the second indenter 47 to achieve the purpose of discharging.
  • the front actuator 29 drives the front connector 33 and the front connector 33 connected to it.
  • the transition plate 43, the rotating block 41, the first 45 indenter, the second indenter 47, and the second cam follower 37 move outward, while the rear actuator 31 drives the rear connector 35 and the cam fork 39 to move outward.
  • the movement distance of the front actuator 29 is controlled to be consistent with the movement distance of the rear actuator 31, and the positions of the cam follower two 37 and the cam fork 39 remain unchanged, so that the rotation block 41 does not occur relative to the transition plate 43. Rotation, that is, the positions of indenter one 45 and indenter two 47 remain unchanged.
  • the front actuator 29 drives the front connecting piece 33 and the transition plate 43 to move, that is, the distance between the indenter two 47 and the indenter three 49 changes, so that the contact surface between the indenter one 45 and the indenter two 47 is two
  • the distance between the contact surface of the indenter three 49 reaches the set value, so that this distance is consistent with the distance between the bent portion two 62 and the bent portion 61 of the flat wire hairpin that needs to be formed.
  • the indenter three 49 on the left molding mechanism and the indenter three 49 on the right molding mechanism can rotate relative to each other. Fold the flat wire hairpin so that the flat wire hairpin produces a bend 61.
  • the pair of rear actuators 31 on the left molding mechanism and the right molding mechanism can be controlled to work, so that the indenter 45 on the left molding mechanism rotates relative to the indenter 2 47 and the right molding mechanism on the The first 45 indenter rotates relative to the second indenter 47, and then the flat wire hairpin is bent and formed, so that the flat wire hairpin generates a second 62 and a third 63.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Power Engineering (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

一种扁线电机定子平面发卡成型装置，包括左右对称设置的两个成型机构，成型机构包括成型模具组件和成型驱动机构，左右对称设置的两个成型模具组件包括：压头三（49）、压头二（47）、以及压头一（45），其中所有压头的顶面设有用于置放扁线直条的成型槽。成型驱动机构用于驱动成型模具组件围绕旋转中心转动以对扁线的中部进行折弯、还用于驱动压头二（47）相对于压头三（49）平移以对扁线的中间折弯段的折弯长度进行调整、以及用于驱动压头一（45）相对于压头二（47）偏转以对扁线的长直腿进行折弯。该成型装置通过不同的执行器位移控制压头移动，对于不同形状的发卡可以通过执行器控制发卡的形状，其适应性强，通用性、工作效率高。

Description

一种扁线电机定子平面发卡成型装置 技术领域
本发明涉及电机的扁线成型技术领域，具体涉及一种扁线电机定子平面发卡成型装置。
背景技术
随着新能源汽车的蓬勃发展，相应的对于电机的需求日益增大，而电机性能的优异与否决定了新能源汽车的性能，传统的圆铜线电机定子绕组由于其方便的装配性而盛行一时，但是随着发展对于电机提出更高的要求，需求体积更小，功能更强，运行速度更快的电机。
与普通绕组相比，扁线绕组在相同的体积下，具有重量轻、效率高，高压下噪音小的特点；从技术角度来说，在同等尺寸下，可通过更大电流，适应更高频率，获取更高品质因数，但是扁线绕组由于其装配的难度较大，目前在国内市场的应用还不广。
其中，为了扁线绕组的性能，发卡层数需要相应的增加，所以一个定子里可能有多层发卡，由于发卡是沿着定子径向一次排布，因此每一层发卡的大小都不相同，而且在有限的空间中布置下发卡，为了发卡之间不干涉需要发卡有相应的避让，这样导致发卡的形状较为复杂。
现有技术发卡成型有的利用简单的机构将扁线弯折成简单的发卡，但是对于形状复杂的发卡就无法实现压装成型，也有的设备只能成型特定形状的发卡，而且需要的成型模具费用较高，现有的技术也存在部分设备能够弯折复杂形状的发卡，但是柔性不够，不能适应多种尺寸的发卡成型。
此外，还有部分扁线成型装置为冲压设备，虽然能将扁线冲压成设定形状，但是对扁线的漆膜损伤比较大，进而会造成电机寿命缩短。
发明内容
为克服现有技术的缺陷，本发明的目的在于提供一种扁线电机定子平面发卡成型装置，以适应成型多种形状尺寸的扁线发卡，满足高通用性的要求。
为此，本发明提出了一种扁线电机定子平面发卡成型装置，包括左右对称设置的两个成型机构，所述成型机构包括成型模具组件和成型驱动机构，左右对称设置的两个成型模具组件包括：居中设置的一对压头三、位于一对压头外侧的一对压头二、以 及位于一对压头二外侧的一对压头一，其中所有压头的顶面设有用于置放扁线直条的成型槽。
所述成型驱动机构用于驱动成型模具组件围绕旋转中心转动以对扁线的中部进行折弯、还用于驱动压头二相对于压头三平移以对扁线的中间折弯段的折弯长度进行调整、以及用于驱动压头一相对于压头二偏转以对扁线的长直腿进行折弯。
进一步地，所述成型驱动机构包括底座、下执行器、圆弧导轨一、圆弧导轨二、下导向块、旋转板、以及凸轮随动器一，所述成型驱动机构用于驱动所述旋转板沿所述圆弧导轨一和圆弧导轨二转动。
所述成型驱动机构还包括前执行器、在前执行器上侧设置的前连接件、以及过渡板，所述成型驱动机构还包括后执行器、在后执行器上侧设置的后连接件、凸轮拨叉、凸轮随动器二、以及转动块，其中，所述转动块的转轴固定连接在所述过渡板。
其中，所述压头一与所述转动块固定连接，所述压头二与过渡板固定连接，所述旋转板与压头三固定连接，所述后执行器用于驱动转动块转动，以带动压头一相对于压头二偏转；所述前执行器和所述后执行器同步运动时用于驱动所述压头二和所述压头一二者整体上相对于压头三平移。
进一步地，所述圆弧导轨一与所述底座之间设有压紧板。
进一步地，所述下执行器位于圆弧导轨一和圆弧导轨二二者之间的夹缝中。
进一步地，所述旋转板上设置有与圆弧导轨一配合的第一滑块和与所述圆弧导轨二配合的第二滑块，其中，第一滑块的位置偏移所述第二滑块的半径方向。
进一步地，所述成型装置用于折弯的平面U型对称发卡和不对称发卡，即发卡包括U型对称发卡和U型不对称发卡。
进一步地，压头二内滑动设置有顶线杆，且顶线杆的顶部能够伸出成型槽内。
进一步地，所述旋转板上设有顶线气缸，且所述顶线气缸与所述顶线杆之间设有顶线过渡杆。
进一步地，顶线杆与所述压头二之间设有弹簧一，所述顶线杆底部设有卡簧一。
进一步地，所述顶线过渡杆设置在所述过渡板与所述转动块连接的转轴中，且所述顶线过渡杆上设有弹簧二，所述顶线过渡杆的底部设置有卡簧二。
与现有技术相比，本发明的有益效果：
1、本发明的扁线电机定子平面发卡成型装置，通过不同的执行器位移控制压头移动，对于不同形状的发卡可以通过电动执行器的位移来控制发卡平面上的形状，其适应性强、通用性高、工作效率高，使用有限型号的模具完成不同形状发卡的成型，降低设计成本和加工成本，提高经济效益；
2、通过设置顶线气缸、顶线杆以及顶线过渡杆，可以将成型后的扁线发卡从压头中的成型槽内取出，实现自动化，提高工作效率，减小人力。
3、本发明的扁线电机定子平面发卡成型装置通过简单的弯折来实现发卡U字型部位的弧形成型，相对于冲压成型而言对扁线的损伤小；同时本发明的整体结构布置紧凑，协调，不产生干涉现象。
除了上面所描述的目的、特征和优点之外，本发明还有其它的目的、特征和优点。下面将参照图，对本发明作进一步详细的说明。
附图说明
构成本申请的一部分的说明书附图用来提供对本发明的进一步理解，本发明的示意性实施例及其说明用于解释本发明，并不构成对本发明的不当限定。在附图中：
图1为本发明的扁线电机定子平面发卡成型装置的轴侧视图；
图2为本发明的扁线电机定子平面发卡成型装置部分结构的轴侧视图；
图3为本发明的扁线电机定子平面发卡成型装置的俯视图；
图4为本发明的扁线电机定子平面发卡成型装置的前视图；
图5为本发明的扁线电机定子平面发卡成型装置的局部机构的剖视图；
图6为本发明的扁线电机定子平面发卡成型装置的局部机构的俯视图；
图7为本发明中扁线发卡成型前直线状态的示意图；以及
图8为使用本发明成型装置能够成型的扁线发卡的形状结构示意图。
附图标记说明
1、底座；3、下执行器；5、圆弧导轨一；7、压紧板；9、圆弧导轨二；11、下导向块；13、顶线气缸；15、顶线过渡杆；17、弹簧二；19、卡簧二；21、顶线杆；23、弹簧一；25、卡簧一；27、旋转板；29、前执行器；31、后执行器；33、前连接件；35、后连接件；37、凸轮随动器二；39、凸轮拨叉；41、转动块；43、过渡板；45、 压头一；47、压头二；49、压头三；51、凸轮随动器一；60、扁线发卡；61、折弯部一；62、折弯部二；63、折弯部三。
具体实施方式
需要说明的是，在不冲突的情况下，本申请中的实施例及实施例中的特征可以相互组合。下面将参考附图并结合实施例来详细说明本发明。
图1-图8示出了根据本发明的一些实施例。
如图1～图6所示，一种扁线电机定子平面发卡成型装置，包括左右对称对称设置的两个成型机构，且两个成型机构的机械结构完全一致，所述成型机构包括成型模具组件和成型驱动机构。
具体地，如图1、图2、图3所示，左右对称设置的两个成型模具组件包括：居中设置的一对压头三49、位于一对压头49外侧的一对压头二47、以及位于一对压头二47外侧的一对压头一45，其中所有压头的顶面设有用于置放扁线直条的成型槽。
所述成型驱动机构包括用于驱动成型模具组件围绕旋转中心转动以对扁线的中部进行折弯、还用于驱动压头二47相对于压头三49平移以对扁线的中间折弯段的折弯长度进行调整、以及还用于驱动压头一45相对于压头二47偏转以对扁线的长直腿进行折弯。
其中，所述成型驱动机构包括底座1、以及安装在底座1上端的下执行器3、圆弧导轨一5、圆弧导轨二9、下导向块11、旋转板27、凸轮随动器一51，其中，旋转板27安装在圆弧导轨一5和圆弧导轨二9上，并与圆弧导轨一5和圆弧导轨二9滑动连接，下导向块11与下执行器3上的滑块固定连接，同时下导向块11通过凸轮随动器一51与旋转板27连接，而旋转板27上设置有压头三49。
其中，所述下执行器3位于圆弧导轨一5和圆弧导轨二9二者之间的夹缝中，同时，所述旋转板27上设置有与圆弧导轨一5配合的第一滑块和与所述圆弧导轨二9配合的第二滑块，其中，第一滑块的位置偏移所述第二滑块的半径方向，即：第一滑块与其所在圆弧圆心形成的连线一，第二滑块与其所在圆弧圆心形成的连线二，连线一与连线二相交而不平行；使下执行器3带动旋转板27在圆弧导轨一5和圆弧导轨二9上移动更加顺畅、平滑。
当左成型机构上的下执行器3和右成型机构上的下执行器3同时工作时，下执行器3可以带动下导向块11直线移动，进而通过凸轮随动器一51带动旋转板27沿圆弧导轨一5和圆弧导轨二9移动，使旋转板27和压头三49在底座1上方转动。
其中，成型机构上的压头三49和右成形机构上的压头三49上端均设有成型槽，由于两个压头三49之间发生相对转动，进而可以对放置在成型槽中的扁线发卡进行折叠，使扁线发卡产生折弯部一61(如图8所示)。
具体地，如图1所示，旋转板27上端固定安装有前执行器29和后执行器31，前连接件33安装于前执行器29的滑块上，过渡板43再固定安装在前连接件33上，转动块41安装在过渡板43上，且转动块41通过转轴与过渡板43转动连接。后连接件35安装于后执行器31的滑块上，凸轮拨叉39固定在后连接件35上端，凸轮随动器二37与转动块41固定连接，且凸轮随动器二37上端位于凸轮拨叉39的腰形槽内。
其中，压头一45固定安装在转动块41前部上端，压头二47则固定安装在过渡板43上，而压头一45和压头二47上均设有成型槽，且两条成型槽共线，可以放置需要成型的平直状态的扁线。
当两个成型机构上的后执行器31工作时，后执行器31带动后连接件35和凸轮拨叉39向外侧直线移动，凸轮随动器二37随凸轮拨叉39移动，进而带动转动块41在过渡板43上绕两者之间的转轴转动，转动块41转动能带动压头一45一起转动；同时，由于前执行器29不工作，使得压头二47与压头三49的相对位置保持不变。通过一对压头一45的转动，可以对扁线发卡60进行折弯成型，使扁线发卡60产生折弯部二62和折弯部三63(如图8所示)。
因此，如图7～图8所示，通过上述结构能够将平直状态的扁线折叠成具有折弯部一61、折弯部二62、以及折弯部三63的平面U型的扁线发卡；其中，U型的扁线发卡包括对称的平面U型发卡和不对称的平面U型发卡。
其中，前执行器29也可以与后执行器31同时工作，前执行器29能带动前连接件33、及安装在前连接件33上的过渡板43、转动块41、压头一45、压头二47、凸轮随动器二37向外侧移动，同时后执行器能带动后连接件35和凸轮拨叉39向外侧移动。
当前执行器29移动的距离与后执行器31移动的距离保持一致时，凸轮随动器二37与凸轮拨叉39的位置保持不变，使转动块41相对于过渡板43不发生转动，即压头一45与压头二47位置保持不变。
然而，由于前执行器29带动前连接件33和过渡板43移动，即压头二47与压头三49之间距离发生变化，使压头一45与压头二47的接触面到两个压头三49的接触面的距离达到设定值，使这个距离与需要成型的扁线发卡中折弯部二62到折弯部一61之间的距离保持一致。
最后通过控制一对后执行器31工作，使两个成型机构上的压头一45发生转动，进而对扁线发卡进行折弯成型，使扁线发卡产生折弯部二62和折弯部三63。从而可以通过电动执行器的位移来控制发卡在空间上的形状，折弯出不同尺寸的扁线发卡。
在一实施例中，如图4、图5所示，过渡板43与转动块41连接的转轴中设置有顶线过渡杆15，顶线过渡杆15上套设有弹簧二17，顶线过渡杆15的底部设置有卡簧二19，卡簧二19用于固定弹簧二17。当顶线过渡杆15安装在转轴内时，弹簧二17处于压缩状态，可以迫使顶线过渡杆15在过渡板43内沿轴线向下运动。
同时，所述压头二47内设置有沿竖直方向直线滑动的顶线杆21，且顶线杆21向上移动时顶部位于压头二47上端的成型槽内。顶线杆21中下部套设有弹簧一23，顶线杆21底部设有卡簧一25，卡簧一25用于固定弹簧一23。当顶线杆21安装在压头二47内时，弹簧一23处于压缩状态，可以迫使顶线杆21在压头二47内沿轴线向下运动。其中，顶线杆21位于顶线过渡杆15上方，顶线杆21下侧设有顶线气缸13，且顶线气缸13固定安装在旋转板27上。
当顶线气缸13轴向移动时，能够顶住顶线过渡杆15向上轴向移动，进而推动顶线杆21在压头二47内向上轴向移动，使顶线杆21顶部凸出于压头二47上面的成型槽底部，从而将成型后的扁线发卡从压头二47上面的中推出来，实现卸料目的。
在一实施例中，如图1，圆弧导轨一5与底座1连接并通过压紧板7压紧，使圆弧导轨一5安装的更加稳定，使旋转板27在圆弧导轨一5上滑动更加平顺。
本发明的扁线电机定子平面发卡成型装置的工作过程如下：
工作过程一
首先，通过控制6个执行器工作，使左侧成型机构上压头一45、压头二47、压头三49的成型槽与右侧成型机构上压头一45、压头二47、压头三49的成型槽共线，再将平直的扁线发卡放置在压头一45、压头二47、压头三49形成的一条平直成型槽内。
然后，通过控制左侧成型机构和右侧成型机构上的一对下执行器3分别直线移动，并使前执行器29和后执行器31处于非工作状态，将下执行器3的直线运动转化为旋转板27的旋转运动，使压头一45、压头二47、压头三49随着旋转板27做旋转运动。其中，左侧成型机构上的压头三49与右侧成型机构上的压头三49发生相对转动，能对扁线发卡进行折叠，使扁线发卡产生折弯部一61。
再然后，通过控制左侧成型机构和右侧成型机构上的一对后执行器31分别工作，使后执行器31带动后连接件35和凸轮拨叉39横向直线移动，凸轮随动器二37随凸轮拨叉39移动，进而带动转动块41在过渡板43上绕两者的转轴转动，转动块41再 带动压头一45转动，同时，由于前执行器29不工作，使得压头二47与压头三49的位置保持不变。
通过左侧成型机构上的压头一45相对于压头二47转动，可以对扁线发卡进行折弯成型，使扁线发卡产生折弯部二62；通过右侧成型机构上的压头一45相对于压头二47转动，可以对扁线发卡进行折弯成型，使扁线发卡产生折弯部三63。
最后，通过控制左侧成型机构和右侧成型机构上的一对顶线气缸13轴向伸缩，能够推动顶线过渡杆15向上轴向移动，进而推动顶线杆21在压头二47内向上轴向移动，使顶线杆21顶部凸出于压头二47上的成型槽底部，从而将成型后的扁线发卡从压头二47上的成型槽中推出来，实现卸料目的。
工作过程二
当需要成型的扁线发卡中折弯部二62到折弯部一61的距离、以及折弯部三63到折弯部一61的距离发生变化时，需要调整成型装置中压头一45与压头三49的相对位置。
首先，通过控制左侧成型机构和右侧成型机构上的一对前执行器29和一对后执行器31同时工作，使前执行器29带动前连接件33、及与前连接件33连接的过渡板43、转动块41、压头一45、压头二47、凸轮随动器二37向外侧移动，同时后执行器31带动后连接件35和凸轮拨叉39向外侧移动。
其中，控制前执行器29的移动距离与后执行器31的移动距离保持一致，使凸轮随动器二37与凸轮拨叉39的位置保持不变，使转动块41相对于过渡板43不发生转动，即压头一45与压头二47位置保持不变。
然而，由于前执行器29带动前连接件33和过渡板43移动，即压头二47与压头三49之间距离发生变化，使压头一45与压头二47的接触面到两个压头三49的接触面的距离达到设定值，使这个距离与需要成型的扁线发卡中折弯部二62到折弯部一61之间的距离保持一致。
然后，通过控制左侧成型机构和右侧成型机构上的一对下执行器3工作，使左侧成型机构上的压头三49与右侧成型机构上的压头三49发生相对转动，能对扁线发卡进行折叠，使扁线发卡产生折弯部一61。
再然后，可以通过控制左侧成型机构和右侧成型机构上的一对后执行器31工作，使左侧成型机构上的压头一45相对于压头二47转动、以及右侧成型机构上的压头一45相对于压头二47转动，进而对扁线发卡进行折弯成型，使扁线发卡产生折弯部二62和折弯部三63。
最后，通过控制左侧成型机构和右侧成型机构上的一对顶线气缸13伸缩，将成型后的扁线发卡从压头二47上的成型槽推出，方便操作人员或者机械手拿取。
以上所述仅为本发明的优选实施例而已，并不用于限制本发明，对于本领域的技术人员来说，本发明可以有各种更改和变化。凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (10)

  1. 一种扁线电机定子平面发卡成型装置，其特征在于，包括左右对称设置的两个成型机构，所述成型机构包括成型模具组件和成型驱动机构，
    左右对称设置的两个成型模具组件包括：居中设置的一对压头三(49)、位于一对压头三(49)外侧的一对压头二(47)、以及位于一对压头二(47)外侧的一对压头一(45)，其中所有压头的顶面设有用于置放扁线直条的成型槽，
    所述成型驱动机构用于驱动成型模具组件围绕旋转中心转动以对扁线的中部进行折弯、还用于驱动压头二(47)相对于压头三(49)平移以对扁线的中间折弯段的折弯长度进行调整、以及用于驱动压头一(45)相对于压头二(47)偏转以对扁线的长直腿进行折弯。
  2. 根据权利要求1所述的扁线电机定子平面发卡成型装置，其特征在于，
    所述成型驱动机构包括底座(1)、下执行器(3)、圆弧导轨一(5)、圆弧导轨二(9)、下导向块(11)、旋转板(27)、以及凸轮随动器一(51)，用于驱动所述旋转板(27)沿所述圆弧导轨一(5)和圆弧导轨二(9)转动，
    所述成型驱动机构还包括前执行器(29)、在前执行器(29)上侧设置的前连接件(33)、以及过渡板(43)，
    所述成型驱动机构还包括后执行器(31)、在后执行器(31)上侧设置的后连接件(35)、凸轮拨叉(39)、凸轮随动器二(37)、以及转动块(41)，其中，所述转动块(41)的转轴固定连接在所述过渡板(43)上，
    其中，所述压头一(45)与所述转动块(41)固定连接，所述压头二(47)与过渡板(43)固定连接，所述旋转板(27)与压头三(49)固定连接，
    所述后执行器(31)用于驱动转动块(41)转动，以带动压头一相对于压头二偏转；所述前执行器(29)和所述后执行器(31)同步运动时用于驱动所述压头二(47)和所述压头一(45)二者整体上相对于压头三(49)平移。
  3. 根据权利要求2所述的扁线电机定子平面发卡成型装置，其特征在于，所述圆弧导轨一(5)与所述底座(1)之间设有压紧板(7)。
  4. 根据权利要求2所述的扁线电机定子平面发卡成型装置，其特征在于，所述下执行器(3)位于圆弧导轨一(5)和圆弧导轨二(9)二者之间的夹缝中。
  5. 根据权利要求2所述的扁线电机定子平面发卡成型装置，其特征在于，用于折弯的平面U型对称发卡和不对称发卡。
  6. 根据权利要求2所述的扁线电机定子平面发卡成型装置，其特征在于，所述旋转板(27)上设置有与圆弧导轨一(5)配合的第一滑块和与所述圆弧导轨二(9)配合的第二滑块，其中，第一滑块的位置偏移所述第二滑块的半径方向。
  7. 根据权利要求2所述的扁线电机定子平面发卡成型装置，其特征在于，所述压头二(47)内滑动设置有顶线杆(21)，且所述顶线杆(21)的顶部能够伸出成型槽内。
  8. 根据权利要求7所述的扁线电机定子平面发卡成型装置，其特征在于，所述旋转板(27)上设有顶线气缸(13)，且所述顶线气缸(13)与所述顶线杆(21)之间设有顶线过渡杆(15)。
  9. 根据权利要求8所述的扁线电机定子平面发卡成型装置，其特征在于，所述顶线杆(21)与所述压头二(47)之间设有弹簧一(23)，所述顶线杆(21)底部设有卡簧一(25)。
  10. 根据权利要求9所述的扁线电机定子平面发卡成型装置，其特征在于，所述顶线过渡杆(15)设置在所述过渡板(43)与所述转动块(41)连接的转轴中，且所述顶线过渡杆(15)上设有弹簧二(17)，所述顶线过渡杆(15)的底部设置有卡簧二(19)。
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