阅读说明：本技术 一种柔性化无刷电机自动绕线工装 (Automatic winding tool for flexible brushless motor ) 是由 易科胜 任武 赵剑平 王磊 赵云飞 岳红云 韩冬 李冬艳 于 2021-08-31 设计创作，主要内容包括：本发明提供了一种柔性化无刷电机自动绕线工装,包括柔性环(9)和固定基座(2),柔性环的内圈与无刷电机铁芯的外圈配合,将无刷电机铁芯固定至所述固定基座的内腔中,固定基座固定至绕线机接口部分旋转轴上。本发明中工装,针对不同结构类型及大小尺寸的无刷电机铁芯,只需设计与无刷电机铁芯大小匹配的柔性环,将无刷电机铁芯及柔性环直接安装于固定基座,无需重新设计加工整套工装,无需反复拆卸固定基座,无需重新调试工装的定位精度,方便快捷地完成工装及铁芯的更换,快速适应不同结构类型铁芯的自动绕线,达到了无刷电机单层及多层漆包线均匀密排的效果,相比人工手动绕线效率至少提升10倍,大幅提升了无刷电机的绕线效率。(The invention provides a flexible automatic winding tool for a brushless motor, which comprises a flexible ring (9) and a fixed base (2), wherein the inner ring of the flexible ring is matched with the outer ring of a brushless motor iron core, the brushless motor iron core is fixed in the inner cavity of the fixed base, and the fixed base is fixed on a rotating shaft of an interface part of a winding machine. According to the tool, aiming at brushless motor cores of different structural types and sizes, only the flexible ring matched with the brushless motor core in size needs to be designed, the brushless motor core and the flexible ring are directly installed on the fixed base, the whole tool does not need to be redesigned and processed, the fixed base does not need to be repeatedly disassembled, the positioning precision of the tool does not need to be debugged, the tool and the core can be conveniently and quickly replaced, the automatic winding of the cores of different structural types can be quickly adapted, the effect of uniform and dense arrangement of single-layer and multi-layer enameled wires of the brushless motor is achieved, compared with manual winding, the winding efficiency is at least improved by 10 times, and the winding efficiency of the brushless motor is greatly improved.)

1. The flexible automatic brushless motor winding tool is characterized by comprising a flexible ring (9) and a fixed base (2), wherein an inner ring of the flexible ring (9) is matched with an outer ring of a brushless motor iron core (10), the brushless motor iron core (10) is fixed in an inner cavity of the fixed base (2), and the upper end face of the fixed brushless motor iron core (10) is close to the upper end face of the fixed base (2) or is flush with the upper end face of the fixed base (2);

the fixing base (2) is of a hollow cylinder structure, according to the height and diameter of a rotating shaft (1) of an interface part of a winding machine, a cavity at the lower part is processed into a stepped hole matched with the diameter of the rotating shaft (1), a hole shoulder (21) of the stepped hole presses the upper part of the rotating shaft (1) to realize axial positioning of the fixing base (2), a threaded fastener I (14) penetrates through the side wall of the fixing base (2), the threaded fastener I (14) is provided with a flat end part (141), the rotating shaft (1) is provided with a local plane, the flat end part (141) of the threaded fastener I (14) is screwed into the local plane on the pressing rotating shaft (1), and circumferential positioning of the fixing base (2) is implemented;

according to the number of pole shoes of the brushless motor, the routing arrangement mode of coils and the wire crossing distance between the coils, a plurality of wire crossing pins (8) are uniformly arranged in the outer circumferential direction of a brushless motor iron core (10) and used for crossing wires of enameled wires between the coils, and a plurality of winding pins (7) are uniformly arranged on the periphery of each wire crossing pin (8) and used for winding the ends of the enameled wires when the coils start to be wound and after the coils are wound.

2. The flexible automatic winding tool for the brushless motor according to claim 1, wherein the number of the winding pins (7) is the same as that of the pole shoes, or 1/2;

the number of the thread crossing needles (8) is single or double that of pole shoes.

3. The flexible automatic winding tool for the brushless motor according to claim 1, wherein at least one through hole is formed in the circumferential side wall of the flexible ring (9), at least one corresponding threaded hole is formed in the circumferential side wall of the fixing base (2), and the threaded fastener III (13) penetrates through the threaded hole in the fixing base (2) and the through hole in the flexible ring (9) to tightly push the brushless motor core (10).

4. The flexible automatic winding tool for the brushless motor according to claim 1, wherein the upper cavity of the fixed base (2) is machined into a stepped hole matched with the diameter of the flexible ring (9), and a hole shoulder of the stepped hole supports the lower part of the flexible ring (9) so as to axially position the flexible ring (9) and the brushless motor core (10).

5. The flexible automatic winding tool for the brushless motor according to claim 1, wherein a positioning block (11) is arranged on the fixed base (2) in a matched manner and used for positioning an angle of an initial circumferential direction after the brushless motor core (10) is installed, and the width of a T-shaped table (111) at the head of the positioning block (11) is matched with a straight groove (102) of the brushless motor core (10); the positioning block (11) is positioned on the fixed base (2) through two positioning pins (12).

6. The flexible automatic winding tool for the brushless motor according to claim 5, wherein the T-shaped table (111) at the head of the positioning block (11) is in clearance fit with the straight groove (102) of the brushless motor iron core (10); the two positioning pins (12) are in interference fit with the positioning blocks (11).

7. The flexible automatic brushless motor winding tool according to claim 5, wherein the number of the positioning pins (12) is two, and the center lines of the two positioning pins (12) pass through the center point of the brushless motor core (10).

8. The flexible automatic brushless motor winding tool as claimed in claim 1, wherein the lower end of the fixing base (2) is a small column section structure with a reduced diameter, a vertical notch groove (22) is axially formed in the small column section structure, a horizontal semicircular groove (23) is formed at a connecting position of the small column section structure and the upper large column section, two free section structures are formed at two ends of the vertical notch groove (22), and a threaded fastener II (15) is matched with opposite threaded holes in the two free sections and is used for locking the fixing base (2) to hold the rotating shaft (1).

9. The flexible automatic brushless motor winding tool according to claim 1, wherein at least one spring pressure groove is formed in the side wall of the fixed base (2), each spring pressure groove is provided with a spring pressing assembly in a matched manner, each spring pressing assembly comprises a spring positioning pin (3), a compression spring (4) and a movable pressing plate (5), and the spring positioning pin (3) is mounted at the lower end of the spring pressure groove and forms interference fit; the compression spring (4) is sleeved on the spring positioning pin (3) and can freely stretch out and draw back on the spring positioning pin (3); the other side of compression spring (4) is installed movable pressing plate (5), the upper end processing of movable pressing plate (5) has chuck (51) with compression spring (4) homonymy, chuck (51) are pressed on the anchor ring of brushless motor iron core (10), movable pressing plate (5) are installed on unable adjustment base (2) through major axis fixed pin (6) of wearing to establish unable adjustment base (2), and can freely rotate around major axis fixed pin (6), make chuck (51) on its upper portion compress tightly brushless motor iron core (10) under compression spring's (4) effect.

10. The flexible automatic winding tool for the brushless motor according to claim 1, wherein the side wall of the fixing base (2) is provided with at least one lightening hole (24).

Technical Field

The invention belongs to the technical field of automatic winding assembly of electromagnetic elements, and particularly relates to a flexible automatic winding tool for a brushless motor, which is suitable for automatic winding of brushless motor cores with different sizes.

Background

The brushless motor is an executing element for providing force or torque, the traditional straight slot iron core type brushless motor adopts a manual winding mode to wind enameled wires on a brushless motor iron core (shown in figure 1), and the problems of easy error of the number of turns of the enameled wires, loose of the enameled wires, low production efficiency, unqualified precision and the like exist, and the brushless motor is seriously dependent on the skill level of workers.

With the high pursuit of the consistency of product quality, the production qualification rate and the production efficiency, automatic winding equipment with various characteristics appears, and the automatic winding equipment is special equipment for winding production of products. According to the different winding methods, the winding method can be divided into 3 types: parallel coil winding machine, fly fork winding machine, threading winding machine. The parallel coil winding machine enables enameled wires to be arranged on a framework or an outer circle of a winding tool in a spiral line mode by a main shaft rotating matching moving mechanism, and is usually used for transformers and hollow coils. The fly fork winding machine drives the fly fork to rotate by a side spindle so that the enameled wire is wound on a framework or an outer groove of a winding tool and is generally used for a motor rotor and a cross instrument coil. The threading and winding machine is used for winding the enameled wire on the framework or an inner annular groove of a winding tool by the linear movement of a main shaft traction guide pin and the matching of a rotating mechanism, and is generally used for products of motor stators and iron cores with special structures.

The general type of winding machine only provides an interface, the movement mode of the winding machine is fixed, and a corresponding automatic winding tool needs to be designed to realize the automatic winding of the brushless motor. If the design is not good, the problems of difficult realization of winding action, movement interference, inconvenient operation, difficult guarantee of winding precision and the like are easily caused.

Disclosure of Invention

In order to overcome the defects in the prior art, the inventor of the invention has carried out intensive research, provides a flexible automatic winding tool suitable for brushless motors with different sizes, realizes the automatic winding technology of straight-slot iron core brushless motors, and greatly improves the winding efficiency of the brushless motors.

The technical scheme provided by the invention is as follows:

a flexible brushless motor automatic winding tool comprises a flexible ring and a fixed base, wherein an inner ring of the flexible ring is matched with an outer ring of a brushless motor iron core, the brushless motor iron core is fixed in an inner cavity of the fixed base, and the upper end surface of the fixed brushless motor iron core is close to the upper end surface of the fixed base or is flush with the upper end surface of the fixed base;

the fixing base is of a hollow cylinder structure, a lower cavity is processed into a stepped hole matched with the diameter of the rotating shaft according to the height and the diameter of the rotating shaft of the interface part of the winding machine, the hole shoulder of the stepped hole tightly presses the upper part of the rotating shaft to realize the axial positioning of the fixing base, a threaded fastener I penetrates through the side wall of the fixing base, the threaded fastener I is provided with a flat end part, the rotating shaft is provided with a local plane, and the flat end part of the threaded fastener I is screwed into the local plane on the tightly-pressing rotating shaft to implement the circumferential positioning of the fixing base;

according to the number of pole shoes of the brushless motor, the routing arrangement mode of the coils and the wire crossing distance between the coils, a plurality of wire crossing needles are uniformly arranged in the outer circumferential direction of an iron core of the brushless motor and used for crossing wires of the enameled wires between the coils, and a plurality of foot winding needles are uniformly arranged on the periphery of each wire crossing needle and used for winding the ends of the enameled wires when the coils start to be wound and after the coils are wound.

In a preferred embodiment, the number of the foot winding needles is the same as that of the pole shoes, or 1/2;

the number of the thread crossing needles is the single-time number or the double-time number of the pole shoes.

In a preferred embodiment, the circumferential side wall of the flexible ring is provided with at least one through hole, the circumferential side wall of the fixing base is provided with at least one corresponding threaded hole, and the threaded fastener III penetrates through the threaded hole in the fixing base (2) and the through hole in the flexible ring to tightly press the brushless motor core.

In a preferred embodiment, the upper cavity of the fixed base is processed into a stepped hole matched with the diameter of the flexible ring, and a hole shoulder of the stepped hole supports the lower part of the flexible ring so as to realize axial positioning of the flexible ring and the brushless motor iron core.

In a preferred embodiment, a positioning block is fittingly installed on the fixed base and used for positioning the angle of the brushless motor core in the initial circumferential direction after installation, and the width of a T-shaped table at the head of the positioning block is matched with the straight slot of the brushless motor core; the positioning block is positioned on the fixed base through two positioning pins.

In a preferred embodiment, the T-shaped table at the head of the positioning block is in clearance fit with the straight slot of the brushless motor iron core; the two positioning pins and the positioning block are in interference fit.

In a preferred embodiment, the number of the positioning pins is two, and the center lines of the two positioning pins pass through the center point of the brushless motor core.

In a preferred embodiment, the lower end of the fixed base is a small column section structure with a reduced diameter, a vertical notch groove is axially formed in the small column section structure, a horizontal semicircular groove is formed in the connecting position of the small column section structure and the upper large column section, two free section structures are formed at two ends of the vertical notch groove, and the threaded fastener II is matched with opposite threaded holes in the two free sections to tightly hold the rotating shaft through locking the fixed base.

In a preferred embodiment, at least one spring pressure groove is formed in the side wall of the fixed base, each spring pressure groove is provided with a spring pressure assembly in a matched manner, each spring pressure groove comprises a spring positioning pin, a compression spring and a movable pressure plate, and the spring positioning pin is arranged at the lower end of the spring pressure groove and forms interference fit; the compression spring is sleeved on the spring positioning pin and can freely stretch out and draw back on the spring positioning pin; the movable pressing plate is installed on the other side of the compression spring, a chuck which is located on the same side as the compression spring is machined at the upper end of the movable pressing plate, the chuck is pressed on the ring surface of the brushless motor iron core, the movable pressing plate is installed on the fixed base through a long shaft fixed pin penetrating through the fixed base and can freely rotate around the long shaft fixed pin, and the chuck on the upper portion of the movable pressing plate is enabled to compress the brushless motor iron core under the action of the compression spring.

In a preferred embodiment, the side wall of the fixing base is provided with at least one lightening hole.

The flexible automatic winding tool for the brushless motor provided by the invention has the following beneficial effects:

(1) according to the flexible automatic winding tool for the brushless motor, the whole tool does not need to be redesigned and processed according to the sizes of different brushless motor iron cores, the iron cores and the flexible rings are directly installed on the fixed base only by designing the flexible rings matched with the sizes of the iron cores, the fixed base does not need to be repeatedly disassembled, the tool and the iron cores can be conveniently and quickly replaced, and the automatic winding tool is quickly suitable for automatic winding of different iron cores.

(2) According to the flexible automatic winding tool for the brushless motor, the winding pins and the cross-line pins are uniformly arranged in the outer circumferential direction of the iron core of the brushless motor, so that cross-line arrangement between coils is facilitated, and phenomena of disorder, winding and the like of cross-lines are prevented.

(3) According to the flexible automatic winding tool for the brushless motor, the positioning accuracy of the brushless motor iron core on the fixing base is guaranteed through the positioning design of the corresponding position of the tool, the fixing base is reliable in positioning accuracy on the rotating shaft and installation, the precision does not need to be adjusted manually and repeatedly, the flexible automatic winding tool can be used after being directly installed, and the difficulty in manually installing and adjusting the tool is reduced.

(4) According to the flexible automatic winding tool for the brushless motor, the elastic pressing assembly is designed, the brushless motor iron core is further axially limited, when the brushless motor iron core is loaded and unloaded, only the lower end of the movable pressing plate needs to be manually pressed, the chuck at the upper part of the movable pressing plate is outwards loosened, and then the pan head screw is loosened, so that the tool and the iron core can be conveniently and quickly replaced.

Drawings

Fig. 1 is a schematic view of a brushless motor core of a straight slot core type brushless motor.

Fig. 2 is an exploded view of a flexible brushless motor automatic winding tool.

Fig. 3 is a schematic view of the installation and positioning of the brushless motor core.

FIG. 4 is a cross-sectional view of a flexible brushless motor automatic winding tool;

FIG. 5 is a side view of a flexible brushless motor automatic winding tool;

FIG. 6 is a view from A-A in FIG. 5;

fig. 7 is a view from B-B in fig. 5.

Description of the reference numerals

The structure comprises a rotating shaft 1, a fixed base 2, a hole shoulder 21, a vertical notch groove 22, a horizontal semicircular groove 23, a rectangular through hole 24, a spring positioning pin 3, a compression spring 4, a movable pressing plate 5, a chuck 51, a long shaft fixing pin 6, a foot winding pin 7, a thread crossing pin 8, a flexible ring 9, a via hole 91, a brushless motor iron core 10, a pole shoe 101, a straight groove 102, a positioning block 11, a T-shaped table 111, a positioning pin 12, a threaded fastener III 13, a threaded fastener I14, a smooth end 141 and a threaded fastener II 15.

Detailed Description

The features and advantages of the present invention will become more apparent and appreciated from the following detailed description of the invention.

The word "exemplary" is used exclusively herein to mean "serving as an example, embodiment, or illustration. Any embodiment described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated.

The invention provides a flexible automatic winding tool suitable for brushless motors with different sizes, which is exemplarily explained by combining the accompanying drawings.

Referring to fig. 2, for brushless motor cores 10 of different sizes, flexible rings 9 with suitable sizes are designed, inner rings of the flexible rings are matched with outer rings of the brushless motor cores, and matching gaps of the flexible rings are suitable in size, so that positioning accuracy of the brushless motor cores 10 is ensured, and the brushless motor cores 10 can be conveniently taken out of the flexible rings 9. According to the size of the outer diameter and the thickness of the flexible ring 9 and considering the axial positioning mode, the fixing base 2 for fixing the flexible ring 9 is designed, the size of the fit clearance is proper, the positioning precision of the flexible ring 9 is guaranteed, and the flexible ring 9 is convenient to clamp.

The description is made by referring to fig. 2, because the cross wires are needed between different coils in the same brushless motor and the ends of the enameled wires need to be wound with feet, according to the number of pole shoes 101 of the brushless motor, the routing arrangement of the coils and the cross wire distance between the coils, the cross wire needles 8 with single or double pole shoe number are uniformly arranged in the outer circumference direction of the brushless motor core 10, so that the cross wires of the enameled wires between the coils are facilitated, the cross wires are prevented from being wound into the coils in the winding process, the foot winding needles 7 with the same pole shoe number or the foot winding needles 7 with 1/2 pole shoe number are uniformly arranged on the periphery of the cross wire needles 8, and the winding of the ends of the enameled wires is facilitated when the coils start winding and after the winding is completed. The crossover needle 8 and the foot winding needle 7 are in clearance fit with the fixed base 2, so that the part of the crossover needle 8 and the foot winding needle 7 can be conveniently pulled and inserted according to actual crossover and foot winding requirements.

As will be described with reference to fig. 3, in order to facilitate accurate positioning of the initial circumferential angle of the brushless motor core 10 after installation, the positioning block 11 is designed to match the width of the core straight slot 102, the width of the head T-shaped stage 111 is in clearance fit with the width of the straight slot 102 of the brushless motor core 10, and the unilateral clearance is 0.01-0.1 mm, such as 0.05mm, so that not only can the circumferential angle of the brushless motor core 10 after installation in the flexible ring 9 be positioned, but also the positioning block 11 can be conveniently taken out of the brushless motor core 10. The positioning block 11 is fixed on the upper end face of the fixing base 2 in the form of two positioning pins 12, the positioning pins 12 and the positioning block 11 are in interference fit, and the central lines of the two positioning pins 12 pass through the central point of the brushless motor iron core 10 to ensure the positioning accuracy in the initial circumferential direction. The flexible ring 9 is provided with at least one through hole 91 in the circumferential direction, and the circumferential side wall of the fixed base 2 is provided with at least one corresponding threaded hole, so that a threaded fastener III 13 such as a pan head screw can penetrate through the fixed base 2 and the flexible ring 9 to further radially push against the brushless motor iron core 10. After the threaded fastener III 13 is installed, the initial circumferential direction angle of the brushless motor core 10 is determined, and the positioning block 11 is taken down.

As described with reference to fig. 2 and 4, according to the height of the flexible ring 9, in order to ensure the axial positioning accuracy of the brushless motor core 10 installed in the fixed base 2, the upper cavity of the fixed base 2 is processed into a stepped hole matching the diameter of the flexible ring 9, and the shoulder of the stepped hole supports the lower part of the flexible ring 9, so as to achieve the axial positioning of the flexible ring 9 and the brushless motor core 10.

Referring to fig. 4 to 7, according to the height and diameter of the rotating shaft 1 of the interface portion of the winding machine, in order to ensure the axial and circumferential positioning accuracy of the fixed base 2 after being installed in the rotating shaft 1, a stepped hole matched with the diameter of the rotating shaft 1 is designed at the center of the bottom of the fixed base 2, the fit clearance of the shaft hole is 0.01 to 0.1mm, such as 0.05mm, and the axial positioning of the fixed base 2 is realized by using the hole shoulder 21 of the stepped hole. A threaded hole is formed at a proper position of a matching part of the fixed base 2 and the rotating shaft 1, the rotating shaft 1 is provided with a partial plane, the end face of a threaded fastener I14 such as a hexagon socket head cap screw is processed to be flat, and the flat end part 141 of the threaded fastener I14 is used for realizing the circumferential positioning of the fixed base 2. The lower extreme of unable adjustment base 2 is the little post section structure that the diameter reduces, vertical breach groove 22 has been seted up to little post section structure axial, and the hookup location department with the big post section in upper portion sets up horizontal half slot 23, makes vertical breach groove 22 both ends form two free segment structures, and threaded fastener II 15 is like the interior hexagonal screw II and two free segment interior relative screw hole cooperations, locks unable adjustment base 2 in order to further hold tightly rotation axis 1. The upper part of the fixed base 2 is provided with lightening holes 24 such as rectangular through holes, so that the weight of the whole tool can be lightened, and the brushless motor iron core 10 and the flexible ring 9 can be conveniently taken out from the lower part to the upper part.

To facilitate axial compression of the brushless motor core 10, a spring positioning pin 3 is mounted at the lower end of the fixed base 2, the spring positioning pin 3 and the fixed base 2 are in interference fit, a compression spring 4 is sleeved on the spring positioning pin 3, and the compression spring 4 can freely move on the spring positioning pin 3, as described with reference to fig. 2, 4 and 5. The other side at compression spring 4 installs movable clamp plate 5, movable clamp plate 5 opens jaggedly in order to prevent the excessive off tracking of compression spring 4, movable clamp plate 5 passes through major axis fixed pin 6 and installs in unable adjustment base 2, movable clamp plate 5 can wind major axis fixed pin 6 free rotation, and make chuck 51 on its upper portion compress tightly brushless motor core 10 under compression spring 4's effect, only need manually press the lower extreme of movable clamp plate 5 simultaneously when packing into and taking out brushless motor core 10, chuck 51 on movable clamp plate 5 upper portion will be outwards loosened. The whole tool comprises two spring positioning pins 3, a compression spring 4, a movable pressing plate 5 and a long shaft fixing pin 6 respectively, and is in a face-to-face symmetrical state relative to the fixing base 2. Certainly, when three or more than three spring pressure grooves are formed in the side wall of the fixed base 2, the whole fixture correspondingly comprises three or more than three spring positioning pins 3, compression springs 4, a movable pressing plate 5 and a long shaft fixing pin 6, and the spring positioning pins, the compression springs, the movable pressing plate and the long shaft fixing pin are uniformly arranged on the fixed base 2 so as to ensure that the brushless motor iron core 10 is reliably axially clamped.

The invention has been described in detail with reference to specific embodiments and illustrative examples, but the description is not intended to be construed in a limiting sense. Those skilled in the art will appreciate that various equivalent substitutions, modifications or improvements may be made to the technical solution of the present invention and its embodiments without departing from the spirit and scope of the present invention, which fall within the scope of the present invention. The scope of the invention is defined by the appended claims.

Those skilled in the art will appreciate that those matters not described in detail in the present specification are well known in the art.