CN-121984294-A - X-pin stator torsion tool penetrating into barrel and torsion process

CN121984294ACN 121984294 ACN121984294 ACN 121984294ACN-121984294-A

Abstract

The invention discloses an X-Pin stator torsion tool and a torsion process for a deep barrel, comprising a stator fixing component and a plurality of layers of torsion barrels which are concentrically arranged, wherein the number of layers of the torsion barrels is the same as that of stator winding layers, each layer of torsion barrels can independently rotate around concentric circles, torsion bosses are arranged on the side parts of the torsion barrels, gaps between two adjacent torsion bosses serve as through torsion grooves for accommodating Pin wires of stator winding ends, the stator fixing component and the torsion barrels are concentrically arranged, the stator fixing component is used for controlling the stator to move so as to twist the Pin wires of the stator winding ends in cooperation with the torsion barrels, and when the torsion barrels are rotated, the Pin wires to be twisted in the torsion grooves are subjected to extrusion force of the front ends of the rear torsion bosses to generate plastic deformation along the torsion direction. The invention has the characteristics of compact structure, convenient operation, high reliability and the like, realizes one line of one groove, avoids the plastic deformation of the copper wire caused by mutual extrusion of the Pin wires to be twisted, and does not generate a straight line segment after twisting.

Inventors

CHEN ZHICHU
HU MING
YANG DIE
YANG BIN
PENG JING
LI HAIBIN
LUO HUIJIAN
Fu Zude
Yi Rukang
SHI JUNXU

Assignees

株洲中车时代电气股份有限公司

Dates

Publication Date: 20260505
Application Date: 20260311

Claims (10)

1. The X-Pin stator torsion tool for the deep barrel is characterized by comprising a stator fixing assembly and a plurality of layers of torsion barrels which are concentrically arranged, wherein the number of layers of the torsion barrels is the same as that of stator winding layers, each layer of torsion barrels can rotate independently around concentric circles, torsion bosses (10) are arranged on the side parts of the torsion barrels, gaps between two adjacent torsion bosses (10) serve as through torsion grooves for accommodating Pin wires of the stator winding ends to be twisted, the stator fixing assembly and the torsion barrels are concentrically arranged, the stator fixing assembly is used for controlling the stator to move so as to twist the Pin wires of the stator winding ends in a matching manner, and when the torsion barrels are rotated, the Pin wires in the torsion grooves are subjected to extrusion force of the front ends of rear torsion bosses (10) to generate plastic deformation along the torsion direction.
2. The X-pin stator torsion tooling of the deep barrel according to claim 1, wherein torsion bosses (10) of even-layer torsion barrels are distributed on the outer wall of the barrel, torsion bosses (10) of odd-layer torsion barrels are distributed on the inner wall of the barrel, and the torsion directions of two adjacent layers of torsion barrels are opposite.
3. The X-pin stator torsion tooling of deep barrels according to claim 2, wherein the upper surface of the torsion boss (10) is provided with an arc chamfer.
4. The X-pin stator torsion tool for deep barrels according to claim 2 is characterized in that the torsion barrels are six layers, namely a first torsion barrel (1), a second torsion barrel (2), a third torsion barrel (4), a fourth torsion barrel (5), a fifth torsion barrel (7) and a sixth torsion barrel (8) from outside to inside in sequence, and check rings are arranged at the tops of the first torsion barrel (1), between the second torsion barrel (2) and the third torsion barrel (4) and between the fourth torsion barrel (5) and the fifth torsion barrel (7).
5. The X-Pin stator torsion tool for deep barrels according to claim 4, wherein the stator fixing assembly comprises a tooth protecting disc (11) and an upper pressing head (22) which are concentrically arranged, the upper pressing head (22) is arranged above the stator, the tooth protecting disc (11) and the torsion barrel are arranged below the stator, the tooth protecting disc (11) is positioned between the torsion barrel and the stator, a plurality of straight line grooves (111) are uniformly distributed on the tooth protecting disc (11), the number of the straight line grooves (111) is consistent with that of stator core grooves, telescopic first tooth protecting teeth (12) are arranged in each straight line groove (111), and the first tooth protecting teeth (12) are used for limiting positions of Pin lines and the stator.
6. The tool for twisting the X-pin stator penetrating into a barrel according to claim 5, wherein the stator fixing assembly further comprises a driving plate (13) concentric with the tooth protecting disc (11), a connecting plate (14) for connecting an external driving part is arranged on the side portion of the driving plate (13), a plurality of arc grooves (131) are uniformly distributed on the driving plate (13), a bolt (17) is arranged at the tail portion of the first tooth protecting part (12), a roller (16) is nested on the bolt (17), the roller (16) is slidably arranged in the arc grooves (131), and when the external driving part drives the driving plate (13) to rotate, the roller (16) drives the bolt (17) to slide along the arc grooves (131) so that the first tooth protecting part (12) stretches out or retracts along the linear groove (111).
7. The tool for twisting the X-pin stator penetrating into the barrel according to claim 6, wherein the tooth protecting disc (11) is further provided with a plurality of rotating shafts (15), bearings (24) are nested on the rotating shafts (15), and the bearings (24) are matched with sliding grooves (132) of the driving plate (13) to assist the driving plate (13) to rotate.
8. The tool for twisting the X-pin stator deep into the barrel according to claim 6, wherein the stator fixing assembly further comprises an iron core positioning ring (18) concentrically arranged with the tooth protecting disc (11), and the driving plate (13) is nested at the periphery of the iron core positioning ring (18).
9. The tool for twisting the X-pin stator penetrating into the barrel according to claim 8, wherein a plurality of key grooves (19) are uniformly distributed on the inner periphery of the iron core positioning ring (18), positioning keys (23) are arranged in the key grooves (19), and the positioning keys (23) are used for positioning the stator iron core.
10. An X-pin stator twisting process, characterized in that it is carried out based on an X-pin stator twisting tooling of any one of claims 1 to 9, going deep into a tub, comprising the steps of: S1, after a stator iron core falls into an iron core positioning ring (18) in a stator fixing assembly, an upper pressure head (22) stretches out to press a stator; S2, an external driving part drives a connecting plate (14) to enable a driving plate (13) to rotate, and under the pushing of an arc-shaped groove (131), a roller (16) and a bolt (17) drive a first tooth protection (12) to extend out along a linear groove (111) so as to limit the positions of Pin lines and stators; S3, the protecting fluted disc (11) and the upper pressure head (22) move to a Pin wire barrel feeding position, and the Pin wire is fed into a torsion groove between two torsion bosses (10); S4, rotating the torsion barrel to start torsion, so that the Pin line deforms along the torsion direction, in the torsion process, synchronously driving the stator to move by the tooth protecting disc (11) and the upper pressure head (22) according to preset parameters, gradually moving the contact point of the Pin line and the torsion boss (10) towards the tail end of the Pin line, gradually sliding the Pin line out along the front side wall of the torsion boss (10), gradually shortening the barrel entering length of the Pin line, and gradually sliding the Pin line out of the torsion groove when the torsion barrel rotates to a specified angle; S5, after torsion is completed, the tooth protecting disc (11) and the upper pressure head (22) are extruded towards the direction close to the torsion barrel, and the twisted Pin line is further extruded; S6, synchronously backing the protective fluted disc (11) and the upper pressure head (22), separating the stator from the torsion barrel, overlapping the end parts of the adjacent X-Pin windings along the radial direction of the torsion barrel, and enabling the Pin line notch to be close to a horizontal state.

Description

X-pin stator torsion tool penetrating into barrel and torsion process Technical Field The invention relates to the technical field of stator torsion processes, in particular to an X-pin stator torsion tool penetrating into a barrel and a torsion process. Background New energy drive motors are facing the core demands for higher power density, lower losses, better NVH (noise, vibration, harshness). Flat wire stators have banned the traditional round wire stators from becoming the mainstay and have further iterated toward multi-slot fine wire. The main advantages of the increased number of grooves are that the torque density is improved, the iron loss is reduced, the NVH performance is improved, the heat dissipation path is improved, the groove fullness rate is improved, the current density can be further improved, the high-frequency alternating current resistance is reduced, and the like. The X-pin winding is compatible with the evolution of multi-slot fine wire as the current mainstream research direction, which presents a great challenge to the torsion process. In the torsion process of the multi-slot thin line X-pin stator, the bending radius needs to be further reduced. At present, when the X-pin stator torsion tool is used for a multi-groove fine wire stator, the X-pin stator torsion tool is affected by the depth of a profiling groove, and the depth of a barrel is shallower, so that the stator torsion transition arc is large, and the size of the end part is high. On the one hand, the existing Hair-pin torsion tool is provided with additional bending steps and needs to be provided with additional straight line segment cutting procedures, on the other hand, if the conventional Hair-pin torsion tool is provided with increased barrel entering depth, in the torsion process, the secondary bending point of a paint film contacted with a torsion notch continuously moves along a copper wire, and the insulation damage risk of the copper wire is extremely high. Therefore, a tooling suitable for twisting and forming the multi-groove thin line X-pin stator copper wire is needed, and the twisting transition arc is reduced and the end height is further shortened under the condition that no straight line segment is generated. Disclosure of Invention Aiming at the defects of the prior art, the invention provides the X-pin stator torsion tool and the torsion process which have compact structure, convenient operation, stability and reliability and go deep into a barrel. In order to solve the technical problems, the invention adopts the following technical scheme: The X-Pin stator torsion tool deep into the barrel comprises a stator fixing assembly and a plurality of layers of torsion barrels which are concentrically arranged, wherein the number of layers of the torsion barrels is the same as that of stator winding layers, each layer of torsion barrels can rotate independently around concentric circles, torsion bosses are arranged on the side parts of the torsion barrels, gaps between two adjacent torsion bosses serve as through torsion grooves for accommodating Pin wires of the stator winding end parts to be twisted, the stator fixing assembly and the torsion barrels are concentrically arranged, the stator fixing assembly is used for controlling the stator to move so as to twist the Pin wires of the stator winding end parts in cooperation with the torsion barrels, and when the torsion barrels are rotated, the Pin wires to be twisted in the torsion grooves are subjected to extrusion force of the front ends of the rear torsion bosses to generate plastic deformation along the torsion direction. As a further improvement of the invention, the torsion bosses of the torsion barrels in even layers are distributed on the outer wall of the barrel, the torsion bosses of the torsion barrels in odd layers are distributed on the inner wall of the barrel, and the torsion directions of the two adjacent torsion barrels in the odd layers are opposite. As a further improvement of the invention, the upper surface of the torsion boss is provided with an arc chamfer. As a further improvement of the invention, the torsion barrels are six layers, namely a first torsion barrel, a second torsion barrel, a third torsion barrel, a fourth torsion barrel, a fifth torsion barrel and a sixth torsion barrel from outside to inside, and check rings are arranged at the top of the first torsion barrel, between the second torsion barrel and the third torsion barrel and between the fourth torsion barrel and the fifth torsion barrel. The stator fixing assembly comprises a protecting tooth disc and an upper pressing head which are concentrically arranged, the upper pressing head is arranged above a stator, the protecting tooth disc and the torsion barrel are arranged below the stator, the protecting tooth disc is positioned between the torsion barrel and the stator, a plurality of straight line grooves are uniformly distributed on the protecting tooth disc, the nu