大线规发卡式漆包膜包线圈成型技术

发卡电机因槽满率高、散热好、体积小、性价比高等优势而广泛应用于新能源汽车领域,但发卡式线圈通常是小线规。与小线规电机相比,大线规电机功率更大。详细阐述了大线规发卡式漆包膜包线圈的结构及成型难点,以及针对冲压成型和挤压成型2种工艺方法在U形成型和端部成型试验验证过程中出现的问题进行了影响分析,并针对出现的导线破损等质量问题在工艺方法、模具、操作等方面进行了改善,最终得到了较满意的线圈成型效果。

Winding Forming of Big Size Enamel Membrane Insulated Hair Pin Winding

Hair pin motor is widely used in new energy vehicles as it has high slot full rate, good heat dissipation, small volume and good cost performance. But its winding is small size electromagnetic wire normally. Compared with small size wire motors, large size wire motors supply more power. The structure and forming difficulties of the big size hair pin enamel membrane insulated winding are described in detail, and the problems appearing during the forming process of the U shaped section and the end by punch forming and extrusion forming techniques are analyzed. The forming technique is optimized in terms of process, mould, wire and operation, and satisfactory winding forming results are obtained.