Method of inserting a hairpin

Patent metadata

Field	Value
Publication number	US-2024128842-A1
Application number	US-202318396303-A
Country	US
Kind code	A1
Filing date	Dec 26, 2023
Priority date	Jun 25, 2020
Publication date	Apr 18, 2024
Grant date	—

Abstract

A method can be used for molding a hairpin inserted into a stator core using a clamping unit that includes a connection bracket mounted on a front end of a robot arm and at least one clamper mounted on the connection bracket. The method includes reciprocally driving the clamping unit in opposite directions in a straight line, and press molding a head portion of the hairpin using a molding jig driven by the at least one clamper.

First claim

What is claimed is:

1 . A method for molding a hairpin inserted into a stator core using a clamping unit that includes a connection bracket mounted on a front end of a robot arm and at least one clamper mounted on the connection bracket, the method comprising:
reciprocally driving the clamping unit in opposite directions in a straight line; and press molding a head portion of the hairpin using a molding jig driven by the at least one clamper.

2 . The method of claim 1 , wherein the at least one clamper comprises a pair of clampers, each of which comprises a first end mounted on the connection bracket and a second end on which a fitting end protrudes; and
wherein reciprocally driving the clamping unit comprises moving the pair of clampers become closer and farther with reference to a central portion of the connection bracket.

3 . The method of claim 2 , further comprising slidably inserting the fitting end into a mounting slot formed in the molding jig.

4 . The method of claim 2 , wherein the press molding uses a mold unit that is detachably coupled with the connection bracket at a position between the pair of clampers by a fixing chuck, wherein the fixing chuck comprises:
a fixing block mounted on the connection bracket; and a plurality of fixing pins disposed along an exterior circumference of the fixing block, the fixing pins being inserted into the fixing block and protruding from the fixing block.

5 . The method of claim 2 , wherein the press molding uses a mold unit that is detachably coupled with the connection bracket at a position between the pair of clampers by a fixing chuck, wherein the mold unit comprises:
a fixing plate coupled to the connection bracket through the fixing chuck; a support bar fixed to the fixing plate; and a pair of molding jigs coupled with pair of clampers; wherein the press molding comprises driving the pair of clampers to move along the support bar to mold the head portion of the hairpin.

6 . A method comprising:
unwinding a coil spiral-wound on an uncoiler; heating the coil; peeling off an insulating film of an enamel material from a portion of the coil; bending the coil in multiple stages to two-dimensionally form a leg portion and a head portion of a hairpin; cutting the coil formed with the leg portion and the head portion by a predetermined length; inserting the hairpin into a stator core using a clamping unit that includes a connection bracket mounted on a front end of a robot arm and at least one clamper mounted on the connection bracket; reciprocally driving the clamping unit in opposite directions in a straight line; and press molding the head portion of the hairpin using a molding jig driven by the at least one clamper.

7 . The method of claim 6 , wherein the at least one clamper comprises a pair of clampers, each of which comprises a first end mounted on the connection bracket and a second end on which a fitting end protrudes; and
wherein reciprocally driving the clamping unit comprises moving the pair of clampers become closer and farther with reference to a central portion of the connection bracket.

8 . The method of claim 7 , further comprising slidably inserting the fitting end into a mounting slot formed in the molding jig.

9 . The method of claim 7 , wherein the press molding uses a mold unit that is detachably coupled with the connection bracket at a position between the pair of clampers by a fixing chuck, wherein the fixing chuck comprises:
a fixing block mounted on the connection bracket; and a plurality of fixing pins disposed along an exterior circumference of the fixing block, the fixing pins being inserted into the fixing block and protruding from the fixing block.

10 . The method of claim 7 , wherein the press molding uses a mold unit that is detachably coupled with the connection bracket at a position between the pair of clampers by a fixing chuck, wherein the mold unit comprises:
a fixing plate coupled to the connection bracket through the fixing chuck; a support bar fixed to the fixing plate; and a pair of molding jigs coupled with pair of clampers; wherein the press molding comprises driving the pair of clampers to move along the support bar to mold the head portion of the hairpin.

11 . The method of claim 6 , wherein bending the coil in multiple stages is performed by a computerized numerical control bending device.

12 . A method comprising:
unwinding a coil spiral-wound on an uncoiler; forming a decoated portion by decoating a predetermined portion of the coil; bending the coil in multiple stages to two-dimensionally form a leg portion and a head portion of a hairpin; cutting the coil formed with the leg portion and the head portion by a predetermined length; inserting the hairpin into a stator core using a clamping unit that includes a connection bracket mounted on a front end of a robot arm and at least one clamper mounted on the connection bracket; reciprocally driving the clamping unit in opposite directions in a straight line; and press molding the head portion of the hairpin using a molding jig driven by the at least one clamper.

13 . The method of claim 12 , wherein the at least one clamper comprises a pair of clampers, each of which comprises a first end mounted on the connection bracket and a second end on which a fitting end protrudes; and
wherein reciprocally driving the clamping unit comprises moving the pair of clampers become closer and farther with reference to a central portion of the connection bracket.

14 . The method of claim 13 , further comprising slidably inserting the fitting end into a mounting slot formed in the molding jig.

15 . The method of claim 13 , wherein the press molding uses a mold unit that is detachably coupled with the connection bracket at a position between the pair of clampers by a fixing chuck, wherein the fixing chuck comprises:
a fixing block mounted on the connection bracket; and a plurality of fixing pins disposed along an exterior circumference of the fixing block, the fixing pins being inserted into the fixing block and protruding from the fixing block.

16 . The method of claim 13 , wherein the press molding uses a mold unit that is detachably coupled with the connection bracket at a position between the pair of clampers by a fixing chuck, wherein the mold unit comprises:
a fixing plate coupled to the connection bracket through the fixing chuck; a support bar fixed to the fixing plate; and a pair of molding jigs coupled with pair of clampers; wherein the press molding comprises driving the pair of clampers to move along the support bar to mold the head portion of the hairpin.

17 . The method of claim 12 , wherein bending the coil in multiple stages is performed by a computerized numerical control bending device.

18 . The method of claim 12 , wherein bending the coil in multiple stages is performed by a press bending device.

19 . The method of claim 12 , wherein forming the decoated portion comprises using a heating device to heat the coil and peel off an insulating film of an enamel material.

Assignees

• Hyundai Motor Co Ltd
• Kia Corp

Inventors

• Choi Seung Min

Classifications

• Y10T29/49002

  Electrical device making · CPC title

• Y10T29/49009

  Dynamoelectric machine · CPC title

• H02K15/064 Primary

  Windings consisting of separate segments · CPC title

• B21D7/06

  in press brakes or between rams and anvils or abutments; Pliers with forming dies · CPC title

• Y10T29/53161

  including deforming means · CPC title