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CN-121972586-A - Cutting and arranging method for multi-turn lead wire before cross welding

CN121972586ACN 121972586 ACN121972586 ACN 121972586ACN-121972586-A

Abstract

The invention relates to the technical field of motor manufacturing, in particular to a cutting and arranging method before multi-turn lead cross welding, which comprises the following steps of S1, carrying out dislocation cutting on two groups of multi-layer stacked leads, enabling cutting surfaces and the axial direction of the leads to form an included angle theta, wherein theta is not equal to 90 DEG k (k is E Z), enabling cutting ends of all layers of cut leads to be staggered in sequence along the stacking direction of the leads, enabling the extending lengths of all layers of leads to be changed monotonously along the stacking direction, S2, butt-jointing the two groups of dislocation cut leads in opposite directions and overlapping the leads layer by layer, arranging a splicing gap between any two adjacent layers of overlapped leads, S3, inserting a connecting piece in the splicing gap, completing the arrangement before cross welding, being higher in efficiency, tidy in head, shorter in operation time consumption, greatly improving welding quality, and reducing secondary correction procedures.

Inventors

  • ZHANG RUI
  • GAO CHENG
  • ZHOU BIN
  • SU DONGXUE
  • YANG YANG
  • ZHAO YI

Assignees

  • 江苏中车电机有限公司

Dates

Publication Date
20260505
Application Date
20251226

Claims (8)

  1. 1. A cutting and arranging method before multi-turn lead wire cross welding comprises the following specific steps: s1, carrying out dislocation cutting on two groups of multi-layer stacked leads (1), wherein a cutting plane and the axial direction of the leads (1) form an included angle theta, wherein theta is not equal to 90 DEG k (k is E Z), cutting ends of each group of cut leads (1) are staggered in sequence along the stacking direction of the leads, and the extension length of each layer of leads is monotonously changed along the stacking direction; S2, butt-jointing two groups of dislocation cut leads (1) in opposite directions and overlapping each other layer by layer, wherein an inserting gap (2) is arranged between any two adjacent layers of overlapped leads (1); S3, inserting a connecting piece (3) into the inserting gap (2) to finish the arrangement before cross welding.
  2. 2. The cutting and arranging method according to claim 1, wherein in step S1, cutting angles of the two groups of the multi-layer stacked leads (1) are mirror symmetry cutting.
  3. 3. The cutting and arranging method according to claim 2, wherein the relation of Δh=d/tan θ is satisfied by an included angle θ between the cutting surface of the staggered cutting and the axial direction of the lead (1), a diameter or an equivalent thickness d of a single lead, and a target amount Δh of the dislocation of the ends of the two adjacent layers of overlapped leads (1) in the direction perpendicular to the axial direction of the lead, and Δh is equal to or greater than d.
  4. 4. The cutting and arranging method according to claim 3, wherein the included angle θ between the cutting surface of the staggered cutting and the axial direction of the lead (1) is in units of degrees, the diameter or equivalent thickness d of the single lead is in units of millimeters, and the target amount Δh of the misalignment of the ends of the two adjacent layers of overlapped leads (1) in the direction perpendicular to the axial direction of the leads is in units of millimeters.
  5. 5. The cutting and arranging method according to claim 1, wherein in step S1, marking is performed on the surface of each layer of the lead (1) along the stacking direction of the lead (1), and then cutting is performed in a staggered manner according to the marking so as to control the uniformity of cutting.
  6. 6. The cutting and arranging method according to claim 1, wherein in step S1, the offset cutting is performed by cutting the single-group multi-layer lead (1) at a time.
  7. 7. The method of claim 1, wherein the wind power generator is a direct-drive, semi-direct-drive or double-fed wind power generator.
  8. 8. The cutting and arranging method according to claim 1, wherein the lead (1) is made of copper or aluminum.

Description

Cutting and arranging method for multi-turn lead wire before cross welding Technical Field The invention relates to the technical field of motor manufacturing, in particular to a cutting and arranging method before multi-turn lead cross welding. Background In a wind power generation system, a stator assembly of a wind power generator is a core component for converting mechanical energy into electric energy, the performance of the stator assembly is indispensible from the efficiency density of a wind turbine generator, a stator coil is formed by connecting a plurality of independent leads in parallel, and the end parts of the stator coil are required to form a complete loop through electric connection. Welding is the only way to meet the low resistance, high mechanical strength, maintenance free requirements. In the steps of cutting and welding the lead, the uniformity of the lead determines whether the subsequent wrapping and hoisting processes can be smoothly performed. Therefore, for the stator assembly of the wind driven generator, multi-turn lead wire cross welding cutting is an important component part of the working procedure, on one hand, the cutting speed directly influences the operation speed and the process, and on the other hand, whether the parallel head after cutting and welding is neat directly influences whether the winding positioning iron core can be lifted or not. If the irregular condition occurs, more time is spent in the manual adjustment link, so that the working procedure is delayed to influence the construction period, and larger loss is caused. In the current stage, in the manufacture of the stator winding coil of the wind driven generator, direct lap joint and layered lap joint are common butt welding methods. The integral direct lap joint is generally applied to wind driven generators with smaller power, the lap joint is compact, space is saved, but the lead contact surface is small, the parallel head current load is easy to cause, and the heat dissipation is poor. The contact area of the layered lapped leads is large, the current passes through the two layers, the heat dissipation effect is excellent, but the space occupation is large, and the corresponding base needs to be enlarged, so that the production cost is increased. The main stream cutting methods used in the existing layered lap joint are mainly divided into two types: The layer-by-layer cutting welding method adopts single-piece layer-by-layer lap cutting for two groups of leads, namely, firstly cutting single lead and vertically butting, and then cutting the subsequent leads layer by layer in an aligned manner. Although the method can ensure that the height difference of the welded joint is smaller, the method has obvious defects, the working hour consumed by cutting welding is higher, and the operation efficiency is low; the whole cutting welding method is to cut the two groups of leads vertically and then insert the leads into each other. The method has higher cutting efficiency, but has the technical problems that the overlapped joint is not neat, the gaps between adjacent leads are not uniform, and the molten metal is easy to bridge to form a short circuit point during welding. The two types of processes have the common defect that the technical requirements of cutting efficiency and merging uniformity cannot be met at the same time. When the head-combining height difference is large, the bonding degree of the insulating material in the follow-up binding procedure is greatly reduced, and the risk of fracture of the connecting point is improved by 3 times due to stress concentration in the hoisting process. At present, a lead cutting process with cutting speed and parallel head quality is needed in the industry so as to improve the manufacturing reliability and production efficiency of the stator assembly of the wind driven generator. Disclosure of Invention The application provides a cutting and arranging method before multi-turn lead wire cross welding, which solves at least one of the problems in the prior art, and adopts the following technical scheme: A cutting and arranging method before multi-turn lead wire cross welding comprises the following specific steps: S1, carrying out dislocation cutting on two groups of multi-layer stacked leads, wherein the cutting surface and the axial direction of the leads form an included angle theta, wherein theta is not equal to 90 DEG k (k epsilon Z), so that the cutting ends of each group of cut leads are staggered in sequence along the stacking direction of the leads, and the extension length of each layer of leads is monotonously changed along the stacking direction; s2, butt-jointing two groups of misplaced lead wires in opposite directions and overlapping the lead wires layer by layer, wherein an inserting gap is arranged between any two adjacent layers of overlapped lead wires; S3, inserting connecting pieces into the inserting gaps to finish arrangement before cross