大线规发卡式漆包膜包线圈成型技术

Winding Forming of Big-Size Enamel-Membrane-Insulated Hair-Pin Winding

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。

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.