Hairpin type stator coil forming method

Patent metadata

Field	Value
Publication number	US-12184134-B2
Application number	US-202217934930-A
Country	US
Kind code	B2
Filing date	Sep 23, 2022
Priority date	Oct 7, 2019
Publication date	Dec 31, 2024
Grant date	Dec 31, 2024

Abstract

In an embodiment a method includes cutting a material coil by a predetermined length, forming a vertex and inclined portions on the material coil, loading the vertex and the inclined portion so as to be interposed between an upper mold and a lower mold, forming the vertex into a front/rear bent portion so that the inclined portions are positioned on different lines based on the vertex by combining the upper and lower molds, loading ends of the inclined portions so as to be interposed between clamping pins and rotating a clamping part so that the inclined portions are rounded in front and rear directions.

First claim

What is claimed is:

1. A method for forming a hairpin type of stator coil, the method comprising:
cutting a material coil to a predetermined length;
forming a vertex and inclined portions on the material coil;
loading the vertex and the inclined portions so as to be interposed between an upper mold and a lower mold;
forming the inclined portions into a front/rear bent portion so that the inclined portions are positioned on different lines based on the vertex by combining the upper and lower molds;
loading ends of the inclined portions into first and second clamping parts so as to be interposed between first and second clamping pins; and
rounding the inclined portions by rotating the first and second clamping parts relative to each other,
wherein cutting the material coil and forming the vertex and the inclined portions comprise:
entering the material coil into an upper portion of a lower central die;
cutting the material coil using a cutting part disposed at a rear side of an entry direction of the material coil;
forming the vertex and the inclined portions on the material coil along a forming surface by moving a moving bracket downward such that a spring part press-fits the material coil to the forming surface of the lower central die; and
moving the moving bracket further downward so that an upper roller part press-fits the material coil along lower left and right dies.

2. The method of claim 1 , wherein forming the vertex and the inclined portions comprises moving the lower left and right dies in left and right directions to be loaded at a predetermined position when the upper roller part moves downward to press-fit the material coil toward the lower left and right dies.

3. The method of claim 1 ,
wherein rotating the first and second clamping parts comprise forming the inclined portions of the material coil to be rounded by rotating the second clamping part in one direction with respect to the first clamping part while the material coil is clamped by the first and second clamping pins.

4. The method of claim 1 , wherein the first clamping part is driven along a guider in a direction closer to or further away from the second clamping part.

5. The method of claim 1 , wherein an amount of the inclined portions being bent is determined according to an angle at which the first clamping part rotates.

Assignees

• Hyundai Motor Co Ltd
• Kia Corp
• Kia Motors Corp

Inventors

• Jang Seungkyu

Classifications

• H02K15/02

  of stator or rotor bodies · CPC title

• B21F3/08

  to flat spiral · CPC title

• Y02T10/64

  Electric machine technologies in electromobility · CPC title

• B21F1/004

  by means of press-type tooling · CPC title

• H02K15/0421 Primary

  and consisting of single conductors, e.g. hairpins · CPC title