CN114094784B

CN114094784B - Forming tool for head of flat copper wire wave winding with small span, large cross section and small end extending torsion lug

Info

Publication number: CN114094784B
Application number: CN202210074573.3A
Authority: CN
Inventors: 王海岗; 宋建成; 张蕊莉; 张亚鸽; 董源利; 王雨星; 王晓勤
Original assignee: Shanxi Fenxi Heavy Industry Co Ltd
Current assignee: Shanxi Fenxi Heavy Industry Co Ltd
Priority date: 2022-01-21
Filing date: 2022-01-21
Publication date: 2022-05-10
Anticipated expiration: 2042-01-21
Also published as: CN114094784A

Abstract

The invention discloses a tooling for forming the head of a flat copper wire wave winding with a small span, a large cross section and a small end extending torsion lug, which realizes the winding of the integral forming of the head of the flat copper wire wave winding with the small span, the large cross section and the small end extending torsion lug. After the twisted lug of the splayed coil with the twisted lug is clamped and fixed mainly through a nose positioning clamping plate and a positioning pin, the bent part of the bevel edge of the head part of the upper coil is bent through the matching of a coil bent part positioning column and a drum-type bending spanner; to the head hypotenuse department of bending of lower floor's coil, through the coil department of bending reference column, the combination cooperation of lower floor's coil hypotenuse pushing down roof beam and the cylinder spanner of bending, realize bending, on the lower bottom surface of lower floor's coil hypotenuse pushing down the roof beam, the inclined plane the same with the inclination of the top face of lower floor's coil hypotenuse has been designed, reached and pushed down the in-process, make lower floor's coil not warp at the downward and inward in-process of bending not damaged, the coil head shaping time has been saved, improve the coil shaping quality, the labor intensity of workers is reduced.

Description

Forming tool for head of flat copper wire wave winding with small span, large cross section and small end extending torsion lug

Technical Field

The invention relates to a winding tool for a motor winding, in particular to a head forming tool and a winding forming method for a flat copper wire wave winding with a small span and a large cross section and a small end extending torsion lug.

Background

Windings in a stator and a rotor of some motors are designed into flat copper wire wave windings, a twisting nose is arranged in the center of the head of each flat copper wire wave winding, an upper coil is a plurality of layers of flat copper wires which are stacked together, a lower coil is also a stacked flat copper wire, a straight line section of the upper coil and a straight line section of the lower coil are arranged in parallel with each other but not in the same plane, and the tail of each winding is arranged into a splayed shape with an outward opening; the wave winding coil realizes inversion transposition of an upper coil and a lower coil which are stacked in multiple layers through a twisting nose, namely, an upper flat copper wire of the upper coil, which is sequentially stacked from top to bottom, is transposed to a lower flat copper wire of the lower coil, which is sequentially stacked from bottom to top, after passing through the twisting nose, so as to realize the purpose of optimizing the performance of the motor winding; the flat type copper wire wave winding that the nose was turned round in the area has the difficult problem of coiling shaping, especially little span, big cross-section, turns round the nose end and stretches little wave winding, and its shaping is just more difficult, and to this kind of winding, the prior art manufacturing process is: firstly, winding a flat copper wire into a shuttle-shaped shape with 5-11 layers stacked, cutting off the arc at one end of the shuttle-shaped coil to form a shuttle-shaped U-shaped coil with an opening at one end, inserting the arc part at the closed end of the shuttle-shaped U-shaped coil into a fixing clamp of a special die, holding two straight edges of the shuttle-shaped U-shaped coil by two hands, and separating the straight edges to the two sides to form a splayed coil with a twisting nose; then bending two straight line sides of the splayed coil to enable the straight line sides to be parallel to each other to form a straight line section of the coil, and obtaining a twisted nose U-shaped coil; finally, bending two opening parts of the tail part of the U-shaped coil with the twisted nose to form an outer splayed tail part section with an outward opening, thereby completing the forming of the flat copper wire wave winding with the twisted nose; for the flat copper wire wave winding with small span, large cross section and small end extending twisting nose, the winding and forming are very difficult through the process.

Aiming at the difficult problem of the winding forming difficulty of the flat copper wire wave winding with the small span, the large cross section and the small end extending and twisting nose, the prior art usually adopts a method formed by welding the twisting nose, and the concrete process is as follows: respectively manufacturing an upper layer flat copper wire coil, a lower layer flat copper wire coil and a twisted nose connecting flat copper wire, then butting the head of the upper layer coil with the head of the lower layer coil, connecting the twisted nose with the flat copper wire, welding each layer of flat copper wire in the upper layer coil and each layer of flat copper wire in the lower layer coil together after transposition and butting, and realizing transposition of the upper and lower layer coil flat copper wires; the twist nose formed by the method has the defects of larger size of the end part of the twist nose and more hidden quality troubles, and also has the defects of complicated manufacturing procedures and longer time consumption; how to design a tool to directly twist and form the flat copper wire integrally and greatly improve the manufacturing efficiency of the flat copper wire becomes a problem to be solved on site; especially, when the twist nose is formed, the bent bevel edge of the head of the lower-layer flat copper wire coil needs to be bent downwards by a certain height so as to enable the distance between the upper layer and the lower layer of the coil to meet the design requirement, and the tool becomes a difficult point of tool design.

After the twisted nose of the flat copper wire wave winding coil is formed, the tail forming process of the wave winding needs to be carried out, and the specific process is as follows: firstly, clamping and fixing the straight edges of the upper and lower layers of windings which are parallel to each other but not in the same plane, and then forming an outer splayed tail section with an outward opening; because the multilayer coil stacks together, especially when the cross-section of flat copper line is great, stack the back together, have the whole very difficult problem of bending, the outward bulge's of department of bending phenomenon appears easily in the in-process of bending, how avoid appearing the bulge to accomplish the afterbody work of bending convenient laborsaving, also be another problem that needs the solution in the frock setting.

Disclosure of Invention

The invention provides a tool for forming the head of a flat copper wire wave winding with a small span, a large cross section and a small end stretching and twisting lug, which realizes the winding of the integral forming of the head of the flat copper wire wave winding with the small span, the large cross section and the small end stretching and twisting lug.

The invention solves the technical problems by the following technical scheme:

the general concept of the invention is: a combined tool capable of meeting the forming of all parts of the flat copper wire wave winding is designed, so that the aim of conveniently realizing the integral one-time complete forming of the flat copper wire wave winding is fulfilled; before the tool is used, the flat copper wire is wound into a stacked shuttle-shaped shape with 5-11 layers, the circular arc at one end of the shuttle-shaped coil is cut off to form a shuttle-shaped U-shaped coil with an opening at one end, the circular arc part at the closed end of the shuttle-shaped U-shaped coil is inserted into a fixing clamp of a special die, and two straight edges of the shuttle-shaped U-shaped coil are held by two hands and are separated towards the two sides, so that the splayed coil with the twisting nose is formed; the tooling takes a splayed coil with a twisting nose as an initial processing coil, and the splayed coil is processed into a flat copper wire wave winding with a small span, a large cross section and a small end extending twisting nose through the tooling; the tool can be divided into a head forming tool part of the wave winding, a straight line edge shaping and fixing tool part and an external splayed tail forming tool part of the wave winding; the head forming tool part of the wave winding is mainly characterized in that after a twisted nose of a splayed coil with the twisted nose is clamped and fixed through a nose positioning clamp plate and a positioning pin, the bent part of the oblique edge of the head of an upper coil is bent through the matching of a coil bent part positioning column and a roller type bending spanner; the bending is realized at the head bevel edge bending part of the lower coil through the combined matching of the coil bending part positioning column, the lower coil bevel edge pressing beam and the drum-type bending wrench, and an inclined plane with the same inclination angle as the top end surface of the lower coil bevel edge is designed on the lower bottom surface of the lower coil bevel edge pressing beam, so that the lower coil is not damaged or deformed in the downward and inward bending process in the pressing process, the coil head forming time is saved, the coil forming quality is improved, and the labor intensity of workers is reduced; the invention mainly comprises two angle steel beams which are parallel to each other and are not on the same horizontal plane, and the angle steel beams are used as a tool mould for shaping and fixing the linear edges of a coil; the tail forming tool part of the wave winding realizes the forming of the splayed tail of the coils with different sizes through the combination of the bending positioning columns at the tail of the coils and different connecting screw holes on the table board, and particularly, an L-shaped clamping plate is arranged at the bending position to effectively limit the outward bulge of the tail coil during bending, so that the defect that the bending position of the tail is bulged outwards and deformed is overcome; in addition, the coil bending positioning column and the drum-type bending wrench are skillfully combined, so that the drum on the wrench extrudes the coil in rolling, and the nondestructive bending molding of the bending position of the wave winding is realized.

A small-span large-section small-end-stretching torsion-nose flat copper wire wave winding head forming tool comprises a tool base and a splayed coil with a torsion-nose; the head of the splayed coil with the twisting nose is provided with the twisting nose, and the twisting nose is provided with the twisting nose hole; an upper coil head forming support platform and an upper coil tail forming support platform are respectively arranged on the rear side of the top end face of the tooling base, a lower coil head forming support platform and a lower coil tail forming support platform are respectively arranged on the front side of the top end face of the tooling base, the height of the top end face of the upper coil head forming support platform is the same as that of the top end face of the upper coil tail forming support platform, the height of the top end face of the lower coil head forming support platform is the same as that of the top end face of the lower coil tail forming support platform, and the height of the top end face of the upper coil head forming support platform is lower than that of the top end face of the lower coil head forming support platform; an upper coil straight line section forming supporting angle iron beam is arranged between the top end surface of an upper coil head forming supporting platform and the top end surface of an upper coil tail forming supporting platform, a lower coil straight line section forming supporting angle iron beam is arranged between the top end surface of a lower coil head forming supporting platform and the top end surface of a lower coil tail forming supporting platform, a twisted nose inserting groove rear vertical plate is arranged on the left front side of the top end surface of the upper coil head forming supporting platform, a twisted nose inserting groove front vertical plate is arranged on the left rear side of the top end surface of the lower coil head forming supporting platform, a twisted nose inserting groove rear vertical plate and a twisted nose inserting groove front vertical plate are arranged between the twisted nose inserting groove rear vertical plate and the twisted nose inserting groove front vertical plate, a twisted nose positioning pin rear penetrating hole is arranged on the twisted nose inserting groove rear vertical plate, a twisted nose positioning pin front penetrating hole is arranged on the twisted nose inserting groove front vertical plate, the top end face of an upper coil head part forming support platform between a vertical plate at the rear part of a twisted nose inserting groove and an upper coil straight line part forming support angle iron cross beam is provided with an upper coil head part bevel edge bending positioning column connecting screw hole, the upper coil head part bevel edge bending positioning column is connected onto the screw hole, the upper coil head part bevel edge bending positioning column is screwed on the upper coil head part bevel edge bending positioning column, the top end face of a lower coil head part forming support platform between the vertical plate at the front part of the twisted nose inserting groove and the lower coil straight line part forming support angle iron cross beam is provided with a lower coil head part bevel edge bending positioning column connecting screw hole, the lower bevel edge bending positioning column of the lower coil head part is connected onto the screw hole, and the lower bevel edge bending positioning column of the lower coil head part is screwed on the lower bevel edge bending positioning column; a threaded upright post for penetrating and connecting the outer end of the lower pressing beam is fixedly arranged on the top end face of the lower coil head forming support table on the front side of the vertical plate at the front part of the twisted nose inserting groove, a bolt upright post is vertically arranged at the center of the top end face of the positioning post bent by the lower bevel edge of the lower coil head, and another bolt upright post is vertically arranged at the center of the top end face of the positioning post bent by the bevel edge of the upper coil head; the twist noses of the splayed coil with the twist noses are inserted into the twist nose insertion grooves, and twist nose limiting pins are connected between the rear part through holes of the twist nose positioning pins and the front part through holes of the twist nose positioning pins in a penetrating manner; the upper-layer coil head of the splayed coil with the twisting nose is abutted against the rear side face of the inclined edge bending positioning column at the upper-layer coil head; the lower-layer coil head of the splayed coil with the twisting nose is abutted against the front side face of the lower bevel edge bending positioning column of the lower-layer coil head, a pressing beam is movably connected between the bolt stand columns on the lower bevel edge bending positioning column of the threaded stand column and the lower-layer coil head in a penetrating manner, the pressing beam is arranged right above the lower-layer coil head of the splayed coil with the twisting nose, a pressing nut is screwed on the top end of the threaded stand column, the top end of the bolt stand column of the lower bevel edge bending positioning column of the lower-layer coil head is screwed on another pressing nut, the pressing nut and the other pressing nut are all in pressing connection with the top end face of the pressing beam.

The lower bottom surface of the lower pressing beam is an inclined surface, and the inclined angle of the lower bottom surface is the same as the inclined angle of the upper top surface of the lower coil of the splayed coil with the twisting nose; the cylinder type bending wrench comprises a cylinder type bending wrench movably sleeved on the top end of a bolt upright post of a lower-layer coil head lower oblique-edge bending positioning column above another lower pressing nut, a bolt upright post cross-connection through hole is formed in the front end of the cylinder type bending wrench, a wrench handle behind the bolt upright post cross-connection through hole is provided with a core column connection screw hole with internal threads, a core column with external threads is screwed in the core column connection screw hole with the internal threads, a locking nut with the external threads is arranged between the top end of the core column with the external threads and the top end face of the wrench handle, a cylinder is movably sleeved at the lower end of the core column with the external threads, the cylinder type bending wrench is movably sleeved at the top end of the bolt upright post of the lower-layer coil head lower oblique-edge bending positioning column through the bolt upright post cross-connection through hole, and the cylinder is abutted to the front side face of the lower-layer coil head of a splayed coil with a twisting nose.

The cylinder type bending wrench comprises a cylinder type bending wrench, a bolt upright column cross-connecting through hole is formed in the front end of a handle of the cylinder type bending wrench, a wrench handle on the rear side of the bolt upright column cross-connecting through hole is provided with a core column connecting screw hole with internal threads, a core column with external threads is connected in the core column connecting screw hole with internal threads, a locking nut with the core column with external threads is arranged between the top end of the core column with external threads and the top end face of the wrench handle, a cylinder is movably sleeved at the lower end of the core column with external threads, the cylinder type bending wrench is movably sleeved on the top end of the bolt upright column of the positioning column with bending on the inclined edge of the head of the upper layer coil through the bolt upright column cross-connecting through hole, and the cylinder abuts against the rear side face of the head of the upper layer coil of the splayed coil with a twisted nose.

A method for forming the head of a flat copper wire wave winding with a small span, a large cross section and a small end extension twisting nose comprises a tool base, a splayed coil with the twisting nose and a drum-type bending spanner, wherein a bolt upright column cross-connection through hole is arranged at the front end of a handle of the drum-type bending spanner, a wrench handle at the rear side of the bolt upright column cross-connection through hole is provided with a core column connecting screw hole with internal threads, a core column with external threads is connected in the core column connecting screw hole with the internal threads, a locking nut with the core column with the external threads is arranged between the top end of the core column with the external threads and the top end face of the wrench handle, and a roller is movably sleeved at the lower end of the core column with the external threads; the head of the splayed coil with the twisting nose is provided with the twisting nose, and the twisting nose is provided with the twisting nose hole; an upper coil head forming support platform and an upper coil tail forming support platform are respectively arranged on the rear side of the top end face of the tooling base, a lower coil head forming support platform and a lower coil tail forming support platform are respectively arranged on the front side of the top end face of the tooling base, the height of the top end face of the upper coil head forming support platform is the same as that of the top end face of the upper coil tail forming support platform, the height of the top end face of the lower coil head forming support platform is the same as that of the top end face of the lower coil tail forming support platform, and the height of the top end face of the upper coil head forming support platform is lower than that of the top end face of the lower coil head forming support platform; an upper coil straight line section forming supporting angle iron beam is arranged between the top end surface of an upper coil head forming supporting platform and the top end surface of an upper coil tail forming supporting platform, a lower coil straight line section forming supporting angle iron beam is arranged between the top end surface of a lower coil head forming supporting platform and the top end surface of a lower coil tail forming supporting platform, a twisted nose inserting groove rear vertical plate is arranged on the left front side of the top end surface of the upper coil head forming supporting platform, a twisted nose inserting groove front vertical plate is arranged on the left rear side of the top end surface of the lower coil head forming supporting platform, a twisted nose inserting groove rear vertical plate and a twisted nose inserting groove front vertical plate are arranged between the twisted nose inserting groove rear vertical plate and the twisted nose inserting groove front vertical plate, a twisted nose positioning pin rear penetrating hole is arranged on the twisted nose inserting groove rear vertical plate, a twisted nose positioning pin front penetrating hole is arranged on the twisted nose inserting groove front vertical plate, the top end face of an upper coil head part forming support platform between a vertical plate at the rear part of a twisted nose inserting groove and an upper coil straight line part forming support angle iron cross beam is provided with an upper coil head part bevel edge bending positioning column connecting screw hole, the upper coil head part bevel edge bending positioning column is connected onto the screw hole, the upper coil head part bevel edge bending positioning column is screwed on the upper coil head part bevel edge bending positioning column, the top end face of a lower coil head part forming support platform between the vertical plate at the front part of the twisted nose inserting groove and the lower coil straight line part forming support angle iron cross beam is provided with a lower coil head part bevel edge bending positioning column connecting screw hole, the lower bevel edge bending positioning column of the lower coil head part is connected onto the screw hole, and the lower bevel edge bending positioning column of the lower coil head part is screwed on the lower bevel edge bending positioning column; a threaded upright post for movably penetrating and connecting the outer end of the lower pressing beam is fixedly arranged on the top end face of the lower coil head forming support table on the front side of the vertical plate at the front part of the twisted nose inserting groove, a bolt upright post is vertically arranged at the center of the top end face of the lower bevel edge bending positioning post of the lower coil head, and another bolt upright post is vertically arranged at the center of the top end face of the upper coil head bevel edge bending positioning post; the method is characterized by comprising the following steps:

inserting a twisting lug on the splayed coil with the twisting lug into a twisting lug insertion groove to enable an upper coil of the splayed coil with the twisting lug to be arranged at the rear part of the top end face of a lower coil head forming support platform and enable the upper coil head of the splayed coil with the twisting lug to be abutted against the rear side face of a bent positioning column at the inclined edge of the upper coil head; the lower-layer coil of the splayed coil with the twisted nose is arranged at the front part of the top end surface of the lower-layer coil head forming support platform, and the lower-layer coil head of the splayed coil with the twisted nose is abutted against the front side surface of the lower oblique edge bending positioning column of the lower-layer coil head;

secondly, inserting a positioning pin between a front part through hole of the twist nose positioning pin and a rear part through hole of the twist nose positioning pin, wherein the inserting positioning pin is inserted in the twist nose hole, and the twist nose is limited and fixed in a twist nose inserting groove;

step three, movably connecting a lower pressing beam between the threaded upright post and a bolt upright post on the top end face of the lower bevel edge bending positioning column of the lower layer coil head in a penetrating manner; the lower bottom surface of the lower pressing beam is an inclined surface, the inclined angle of the lower bottom surface is the same as the inclined angle of the upper top surface of the lower coil of the splayed coil with the twisting nose, one end of the lower pressing beam is provided with a through hole, and the lower pressing beam is movably sleeved on the threaded upright post through the through hole; the other end of the lower pressing beam is provided with another through hole, and the lower pressing beam is movably sleeved on a bolt upright post on the top end face of the lower bevel edge bending positioning column of the lower layer coil head through the other through hole;

fourthly, screwing a lower pressing nut on the top end of the threaded upright post, and screwing the other lower pressing nut on the bolt upright post on the top end face of the lower bevel edge bending positioning column of the head of the lower coil; the lower pressing beam downwards presses the head of the lower coil of the splayed coil with the twisting nose by rotating the lower pressing nut and the other lower pressing nut until the head of the lower coil of the splayed coil with the twisting nose is abutted against the top end face of the lower coil head forming support table, so that the lower coil is bent downwards, and the height difference between the lower coil and the upper coil meets the design requirement;

and fifthly, taking the drum-type bending wrench, sleeving a bolt upright column cross-connecting through hole arranged at the front end of the drum-type bending wrench on a bolt upright column on the top end face of the lower bevel edge bending positioning column of the lower-layer coil head, enabling a roller on the drum-type bending wrench to abut against the front side face of the lower-layer coil head of the splayed coil with the twisting nose, rotating the drum-type bending wrench anticlockwise, enabling the roller to rotate along an arc line, taking the lower-layer coil head of the splayed coil with the twisting nose as a supporting point, bending the lower bevel edge of the lower-layer coil head in the right-rear direction by taking the lower bevel edge bending positioning column of the lower-layer coil head as a supporting point, and bending and forming the lower bevel edge of the lower-layer coil head.

Sixthly, taking the roller type bending wrench down from the bolt upright post on the top end face of the lower oblique edge bending positioning column of the lower-layer coil head, then sleeving the roller type bending wrench on the other bolt upright post on the top end face of the upper-layer oblique edge bending positioning column of the upper-layer coil head, and enabling a roller on the roller type bending wrench to abut against the rear side face of the upper-layer coil head of the splayed coil with the twisting nose;

and seventhly, rotating the roller type bending wrench clockwise, wherein the roller rotates along an arc line, and the upper-layer coil head part of the splayed coil with the twisting nose is bent to the right front direction by taking the bent positioning column at the inclined edge of the upper-layer coil head part as a supporting point to form the inclined edge of the upper-layer coil head part.

The invention realizes integral bending of the head of the flat copper wire wave winding stacked in multiple layers, realizes integral forming of the flat copper wire wave winding in multiple layers, and particularly realizes one-time forming of the lower bevel edge and the straight line segment of the head of the coil, thereby improving the forming quality of the coil and greatly improving the production efficiency of coil winding.

Drawings

FIG. 1 is a schematic structural view of the inventive tool during bending of the head of a lower coil;

FIG. 2 is a schematic structural view of the present invention when bending the head of the upper coil;

FIG. 3 is a schematic structural view of a fixed table of the tool of the present invention;

FIG. 4 is a schematic structural view of a fixed table top of the tool of the present invention when an upper bending positioning column and a turning plate type eccentric wheel clamping mechanism are installed;

FIG. 5 is a schematic diagram of the structure of the splayed coil with twist noses of the present invention;

fig. 6 is a schematic structural view of a hold-down beam 801 of the present invention;

FIG. 7 is a schematic diagram of a barrel bending wrench 701 according to the present invention;

fig. 8 is a schematic structural diagram of the lower bevel-edge-bent positioning column 201 of the lower coil header of the invention;

FIG. 9 is a schematic structural diagram of a twisted-nose U-shaped coil obtained after the head of the flat copper wire wave winding is molded;

FIG. 10 is a schematic structural view of a small-span, large-cross-section, small-end-extension-torsion-lug flat copper wire wave winding formed by winding;

fig. 11 is a schematic view of the structure of the present invention when bending the first bending edge 408 of the tail portion of the lower coil;

fig. 12 is a schematic structural view of the present invention when bending the second bending edge 409 of the tail portion of the lower coil;

FIG. 13 is a schematic view of the structure of the present invention after the winding has been fully bent;

FIG. 14 is a schematic view of the lower coil right panel eccentric clamping mechanism 302 of the present invention;

fig. 15 is a schematic structural view of the flap 311 of the present invention;

FIG. 16 is a schematic structural view of the stepped eccentric post 315 of the present invention;

FIG. 17 is a schematic diagram of the construction of the coil linear side compact 316 of the present invention;

fig. 18 is a schematic structural view of an L-shaped stopper plate 601 of the present invention.

Detailed Description

The invention is described in detail below with reference to the accompanying drawings:

a small-span large-section small-end-stretching torsion-nose flat copper wire wave winding head forming tool comprises a tool base 1 and a splayed coil with a torsion-nose; the head of the splayed coil with the twisting nose is provided with the twisting nose 401, and the twisting nose 401 is provided with a twisting nose hole 410; an upper coil head forming support platform 101 and an upper coil tail forming support platform 102 are respectively arranged on the rear side of the top end face of the tooling base 1, a lower coil head forming support platform 103 and a lower coil tail forming support platform 104 are respectively arranged on the front side of the top end face of the tooling base 1, the height of the top end face of the upper coil head forming support platform 101 is the same as that of the top end face of the upper coil tail forming support platform 102, the height of the top end face of the lower coil head forming support platform 103 is the same as that of the top end face of the lower coil tail forming support platform 104, and the height of the top end face of the upper coil head forming support platform 101 is lower than that of the top end face of the lower coil head forming support platform 103; an upper coil straight line section forming supporting angle iron beam 105 is arranged between the top end surface of an upper coil head forming supporting platform 101 and the top end surface of an upper coil tail forming supporting platform 102, a lower coil straight line section forming supporting angle iron beam 106 is arranged between the top end surface of a lower coil head forming supporting platform 103 and the top end surface of a lower coil tail forming supporting platform 104, a twisted nose inserting groove rear vertical plate 107 is arranged on the left front side of the top end surface of the upper coil head forming supporting platform 101, a twisted nose inserting groove front vertical plate 108 is arranged on the left rear side of the top end surface of the lower coil head forming supporting platform 103, a twisted nose inserting groove 109 is formed between the twisted nose inserting groove rear vertical plate 107 and the twisted nose inserting groove front vertical plate 108, a twisted nose rear penetrating hole 110 is arranged on the twisted nose inserting groove rear vertical plate 107, and a positioning pin is arranged on the twisted nose inserting groove front vertical plate 108, a front through hole 111 of a twist-nose positioning pin is arranged, an upper coil head inclined edge bending positioning column connecting screw hole 118 is arranged on the top end face of an upper coil head forming supporting platform 101 between a rear vertical plate 107 of the twist-nose inserting groove and an upper coil straight line forming supporting angle iron cross beam 105, an upper coil head inclined edge bending positioning column connecting screw hole 118 is arranged on the upper coil head inclined edge bending positioning column connecting screw hole 118, an upper coil head inclined edge bending positioning column 202 is screwed on the upper coil head inclined edge bending positioning column 202, a lower coil head inclined edge bending positioning column connecting screw hole 113 is arranged on the top end face of a lower coil head forming supporting platform 103 between a front vertical plate 108 of the twist-nose inserting groove and a lower coil straight line forming supporting angle iron cross beam 106, and a lower coil head inclined edge bending positioning column 201 is screwed on the lower coil head inclined edge bending positioning column connecting screw hole 113; a threaded upright column 112 for penetrating and connecting the outer end of a lower pressing beam is fixedly arranged on the top end face of the lower coil head forming support table 103 on the front side of the vertical plate 108 at the front part of the twisted nose inserting groove, a bolt upright column is vertically arranged at the center of the top end face of the lower bevel edge bending positioning column 201 of the lower coil head, and another bolt upright column is vertically arranged at the center of the top end face of the upper coil head bevel edge bending positioning column 202; a twist nose 401 of the splayed coil with the twist nose is inserted in the twist nose insertion groove 109, and a twist nose limiting pin 501 is inserted between the rear part through hole 110 of the twist nose positioning pin and the front part through hole 111 of the twist nose positioning pin; the upper-layer coil head of the splayed coil with the twisting nose is abutted against the rear side face of the bevel edge bending positioning column 202 of the upper-layer coil head; the lower-layer coil head of the splayed coil with the twist nose is abutted against the front side face of the lower bevel edge bending positioning column 201 of the lower-layer coil head, a pressing beam 801 is movably connected between the threaded upright column 112 and a bolt upright column on the lower bevel edge bending positioning column 201 of the lower-layer coil head in a penetrating mode, the pressing beam 801 is arranged right above the lower-layer coil head of the splayed coil with the twist nose, a pressing nut 901 is screwed at the top end of the threaded upright column 112, another pressing nut is screwed at the top end of the bolt upright column of the lower bevel edge bending positioning column 201 of the lower-layer coil head, and the pressing nut 901 and the another pressing nut are connected on the top end face of the pressing beam 801 in a pressure-sharing mode.

The lower bottom surface 8011 of the lower pressing beam 801 is an inclined surface, and the inclined angle of the lower bottom surface 8011 is the same as the inclined angle of the upper top surface of the lower coil of the splayed coil with the twisted nose; a roller type bending wrench 701 is movably sleeved at the top end of the bolt upright post of the lower-layer coil head lower oblique edge bending positioning column 201 above the other pressing nut, the front end of the drum-type bending wrench 701 is provided with a bolt upright post through hole 7011, a core column connecting screw hole with internal threads is arranged on the wrench handle at the rear side of the bolt upright post penetrating through hole 7011, a core column 7012 with external threads is screwed in the core column connecting screw hole with internal threads, a locking nut with the external thread stem 7012 is arranged between the top end of the stem 7012 with the external thread and the top end surface of the wrench handle, a roller 7013 and a roller bending wrench 701 are movably sleeved at the lower end of the core column 7012 with the external thread, the cylinder 7013 is movably sleeved on the top end of the bolt upright post of the lower bevel edge bending positioning column 201 of the lower coil head part through the bolt upright post penetrating through hole 7011, and abuts against the front side surface of the lower coil head part of the splayed coil with the twisting nose.

A roller type bending wrench 701 is movably sleeved at the top end of the other bolt upright column on the upper-layer coil head oblique edge bending positioning column 202, a bolt upright post cross-connecting through hole 7011 is arranged at the front end of the handle of the drum type bending wrench 701, a wrench handle at the rear side of the bolt upright post cross-connecting through hole 7011 is provided with a core column connecting screw hole with internal threads, a stem 7012 with external threads is connected in the stem connecting screw hole with the internal threads, a locking nut 7012 with the external threads is arranged between the top end of the stem 7012 with the external threads and the top end surface of the wrench handle, a roller 7013 and a roller bending wrench 701 are movably sleeved at the lower end of the core column 7012 with the external thread, the top end of the bolt upright post of the bevel edge bending positioning column 202 of the head part of the upper layer coil is movably sleeved by the bolt upright post through-connecting the through hole 7011, and the roller 7013 is abutted against the rear side surface of the head part of the upper layer coil of the splayed coil with the twisting nose.

A method for forming the head of a flat copper wire wave winding with a small span, a large cross section and a small end extension twisting nose comprises a tooling base 1, a splayed coil with a twisting nose and a roller type bending spanner 701, wherein a bolt upright post cross-connection through hole 7011 is arranged at the front end of a handle of the roller type bending spanner 701, a core column connecting screw hole with internal threads is arranged on a spanner handle at the rear side of the bolt upright post cross-connection through hole 7011, a core column with external threads 7012 is connected in a core column connecting screw hole with internal threads, a locking nut with the external threads 7012 is arranged between the top end of the core column with external threads 7012 and the top end face of the spanner handle, and a roller 7013 is movably sleeved at the lower end of the core column with external threads 7012; the head of the splayed coil with the twisting nose is provided with the twisting nose 401, and the twisting nose 401 is provided with a twisting nose hole 410; an upper coil head forming support platform 101 and an upper coil tail forming support platform 102 are respectively arranged on the rear side of the top end face of the tooling base 1, a lower coil head forming support platform 103 and a lower coil tail forming support platform 104 are respectively arranged on the front side of the top end face of the tooling base 1, the height of the top end face of the upper coil head forming support platform 101 is the same as that of the top end face of the upper coil tail forming support platform 102, the height of the top end face of the lower coil head forming support platform 103 is the same as that of the top end face of the lower coil tail forming support platform 104, and the height of the top end face of the upper coil head forming support platform 101 is lower than that of the top end face of the lower coil head forming support platform 103; an upper coil straight line section forming supporting angle iron beam 105 is arranged between the top end surface of an upper coil head forming supporting platform 101 and the top end surface of an upper coil tail forming supporting platform 102, a lower coil straight line section forming supporting angle iron beam 106 is arranged between the top end surface of a lower coil head forming supporting platform 103 and the top end surface of a lower coil tail forming supporting platform 104, a twisted nose inserting groove rear vertical plate 107 is arranged on the left front side of the top end surface of the upper coil head forming supporting platform 101, a twisted nose inserting groove front vertical plate 108 is arranged on the left rear side of the top end surface of the lower coil head forming supporting platform 103, a twisted nose inserting groove 109 is formed between the twisted nose inserting groove rear vertical plate 107 and the twisted nose inserting groove front vertical plate 108, a twisted nose rear penetrating hole 110 is arranged on the twisted nose inserting groove rear vertical plate 107, and a positioning pin is arranged on the twisted nose inserting groove front vertical plate 108, a front through hole 111 of a twist-nose positioning pin is arranged, an upper coil head inclined edge bending positioning column connecting screw hole 118 is arranged on the top end face of an upper coil head forming supporting platform 101 between a rear vertical plate 107 of the twist-nose inserting groove and an upper coil straight line forming supporting angle iron cross beam 105, an upper coil head inclined edge bending positioning column connecting screw hole 118 is arranged on the upper coil head inclined edge bending positioning column connecting screw hole 118, an upper coil head inclined edge bending positioning column 202 is screwed on the upper coil head inclined edge bending positioning column 202, a lower coil head inclined edge bending positioning column connecting screw hole 113 is arranged on the top end face of a lower coil head forming supporting platform 103 between a front vertical plate 108 of the twist-nose inserting groove and a lower coil straight line forming supporting angle iron cross beam 106, and a lower coil head inclined edge bending positioning column 201 is screwed on the lower coil head inclined edge bending positioning column connecting screw hole 113; a threaded upright column 112 for movably penetrating and connecting the outer end of the lower pressing beam is fixedly arranged on the top end face of the lower coil head forming support table 103 on the front side of the vertical plate 108 at the front part of the twisted nose inserting groove, a bolt upright column is vertically arranged at the center of the top end face of the positioning column 201 bent at the lower bevel edge of the lower coil head, and another bolt upright column is vertically arranged at the center of the top end face of the positioning column 202 bent at the bevel edge of the upper coil head; the method is characterized by comprising the following steps:

firstly, inserting a twisting lug 401 on the splayed coil with the twisting lug into a twisting lug insertion groove 109, so that an upper-layer coil of the splayed coil with the twisting lug is arranged at the rear part of the top end face of a lower-layer coil head forming support platform 103, and the head part of the upper-layer coil of the splayed coil with the twisting lug is abutted to the rear side face of a bent positioning column 202 at the inclined edge of the head part of the upper-layer coil; arranging a lower-layer coil of the splayed coil with the twisted nose at the front part of the top end surface of the lower-layer coil head forming support platform 103, and enabling the lower-layer coil head of the splayed coil with the twisted nose to be abutted against the front side surface of the lower bevel edge bending positioning column 201 of the lower-layer coil head;

secondly, inserting a positioning pin 501 between a front part through hole 111 of the twist-nose positioning pin and a rear part through hole 110 of the twist-nose positioning pin, wherein the inserting positioning pin 501 is inserted in the twist-nose hole 410 in a penetrating manner, and limiting and fixing the twist nose 401 in the twist-nose inserting groove 109;

thirdly, movably connecting a lower pressing beam 801 between the threaded upright column 112 and a bolt upright column on the top end face of the lower bevel edge bending positioning column 201 of the lower coil head; the lower bottom surface 8011 of the lower pressing beam 801 is an inclined surface, the inclined angle of the lower bottom surface 8011 is the same as the inclined angle of the upper top surface of the lower coil of the splayed coil with the twisted nose, one end of the lower pressing beam 801 is provided with a through hole, and the lower pressing beam 801 is movably sleeved on the threaded upright column 112 through the through hole; the other end of the lower pressing beam 801 is provided with another through hole, and the lower pressing beam 801 is movably sleeved on a bolt upright post on the top end face of the lower bevel edge bending positioning column 201 of the lower coil head through the other through hole;

fourthly, screwing a lower pressing nut 901 on the top end of the threaded upright post 112, and screwing another lower pressing nut on a bolt upright post on the top end face of the lower bevel edge bending positioning column 201 of the head part of the lower coil; the lower pressing beam 801 downwards presses the head of the lower coil of the splayed coil with the twisting nose by rotating the lower pressing nut 901 and the other lower pressing nut until the head of the lower coil of the splayed coil with the twisting nose is abutted against the top end surface of the lower coil head forming support table 103, so that the lower coil is bent downwards, and the height difference between the lower coil and the upper coil meets the design requirement;

fifthly, taking a roller type bending wrench 701, enabling a bolt upright post penetrating through hole 7011 arranged at the front end of the roller type bending wrench 701 to be sleeved on the bolt upright post on the top end face of the lower bevel edge bending positioning column 201 of the lower coil head, enabling a roller 7013 on the roller type bending wrench 701 to abut against the front side face of the lower coil head of the splayed coil with the twisted nose, rotating the roller type bending wrench 701 anticlockwise, enabling the roller 7013 to rotate along an arc line, enabling the lower coil head of the splayed coil with the twisted nose to be bent towards the right rear direction by taking the lower bevel edge bending positioning column 201 of the lower coil head as a supporting point, and bending and forming a lower bevel edge 406 of the lower coil head;

the initial workpiece of the coil head bending tool is a splayed coil with a twisting nose, and the splayed coil with the twisting nose is processed into a U-shaped coil with the twisting nose through the head bending tool; the invention relates to a method for manufacturing a splayed coil with a twisted nose, which is characterized in that after the initial workpiece, namely the splayed coil with the twisted nose, is machined and formed by the twisted nose in the previous stage, the height difference between an upper coil and a lower coil is larger than the design height, so that when the head of the splayed coil is bent and formed, the bent inclined edge of the head of the lower coil is bent downwards to reduce the distance between the upper coil and the lower coil and meet the load design requirement, and therefore, the inclined edge at the bent position of the head of the lower coil is called as a lower inclined edge and has the meaning of bending downwards.

Sixthly, taking the roller type bending wrench 701 down from the bolt upright column on the top end face of the lower bevel edge bending positioning column 201 of the lower coil head, then sleeving the roller type bending wrench 701 on the other bolt upright column on the top end face of the upper bevel edge bending positioning column 202 of the upper coil head, and enabling a roller 7013 on the roller type bending wrench 701 to abut against the rear side face of the upper coil head of the splayed coil with the twisting nose;

and seventhly, rotating the roller type bending wrench 701 clockwise, rotating the roller 7013 along an arc line, bending the upper-layer coil head part of the splayed coil with the twisting nose to the right front direction by taking the bending positioning column 202 at the inclined edge of the upper-layer coil head part as a supporting point, and bending and molding the inclined edge 402 of the upper-layer coil head part.

A small-span large-section small-end torsion-lug flat copper wire wave winding tail forming tool comprises a tool base 1 and a torsion-lug U-shaped coil, wherein the tool takes the torsion-lug U-shaped coil as an initial workpiece, and the torsion-lug U-shaped coil is bent and formed into a small-span large-section small-end torsion-lug flat copper wire wave winding through the tool; an upper coil head forming support platform 101 and an upper coil tail forming support platform 102 are respectively arranged on the rear side of the top end face of the tooling base 1, a lower coil head forming support platform 103 and a lower coil tail forming support platform 104 are respectively arranged on the front side of the top end face of the tooling base 1, the height of the top end face of the upper coil head forming support platform 101 is the same as that of the top end face of the upper coil tail forming support platform 102, the height of the top end face of the lower coil head forming support platform 103 is the same as that of the top end face of the lower coil tail forming support platform 104, and the height of the top end face of the upper coil head forming support platform 101 is lower than that of the top end face of the lower coil head forming support platform 103; an upper coil straight-line section forming supporting angle iron beam 105 is arranged between the top end surface of an upper coil head forming supporting platform 101 and the top end surface of an upper coil tail forming supporting platform 102, a lower coil straight-line section forming supporting angle iron beam 106 is arranged between the top end surface of a lower coil head forming supporting platform 103 and the top end surface of a lower coil tail forming supporting platform 104, a right front turning plate hinging seat 115 is arranged at the upper right end of the lower coil straight-line section forming supporting angle iron beam 106, the lower coil straight line edge of a twist nose U-shaped coil abuts against an angle iron groove of the lower coil straight-line section forming supporting angle iron beam 106, a lower coil right turning plate type eccentric wheel clamping mechanism 302 is hinged on the right front turning plate hinging seat 115, and the lower coil right turning plate type eccentric wheel clamping mechanism 302 and the lower coil forming supporting angle iron beam 106 are arranged between the lower coil right turning plate type eccentric wheel clamping mechanism 302 and the lower coil forming supporting angle iron beam 106, the lower coil straight edge 407 is clamped; a lower-layer coil right-part plate-turning type eccentric wheel clamping mechanism 302 and a lower-layer coil left-part plate-turning type eccentric wheel clamping mechanism 301 are respectively arranged on the lower-layer coil straight-line section forming supporting angle iron cross beam 106, an upper-layer coil right-part plate-turning type eccentric wheel clamping mechanism 304 and an upper-layer coil left-part plate-turning type eccentric wheel clamping mechanism 303 are respectively arranged on the upper-layer coil straight-line section forming supporting angle iron cross beam 105, the four plate-turning type eccentric wheel clamping mechanisms are completely identical in structure, and the straight line edges of the coils can be shaped through the four plate-turning type eccentric wheel clamping mechanisms; a lower coil tail bending first positioning column connecting screw hole 119 and a lower coil tail bending second positioning column connecting screw hole 120 are respectively arranged on the top end surface of the lower coil tail forming support platform 104, a lower coil tail bending first positioning column 203 is connected on the lower coil tail bending first positioning column connecting screw hole 119, a lower coil tail bending second positioning column 204 is connected on the lower coil tail bending second positioning column connecting screw hole 120, a threaded column is vertically arranged at the center of the top end surface of the lower coil tail bending first positioning column 203, a threaded column is vertically arranged at the center of the top end surface of the lower coil tail bending second positioning column 204, an L-shaped limiting plate 601 is inserted on the threaded column arranged at the center of the top end surface of the lower coil tail bending second positioning column 204, a U-shaped notch is arranged on the horizontal plate of the L-shaped limiting plate 601, the L-shaped limiting plate 601 is connected to a threaded upright column arranged in the center of the top end face of the lower coil tail bending second positioning column 204 in an inserting mode through a U-shaped notch, and a lower coil tail first bending edge 408 of the flat copper wire wave winding is arranged between a vertical plate of the L-shaped limiting plate 601 and the outer side face of the lower coil tail bending second positioning column 204.

The lower coil right turning plate type eccentric wheel clamping mechanism 302 is formed by combining a turning plate 311, an eccentric column 315 with a step, a coil linear edge pressing block 316 and a rotating handle 314; the turning plate 311 is hinged on a right front turning plate hinge seat 115 on the lower coil straight line section forming support angle iron beam 106 through a pair of hinge tongues 3112 on the turning plate 311, and an eccentric column hanging hole 3111 is formed on the turning plate 311; a first step column 317 is eccentrically and fixedly arranged on the top end surface of the stepped eccentric column 315, a rotary handle connecting block 318 is fixedly connected on the top end surface of the first step column 317, and a threaded second step column 312 is fixedly connected on the top end surface of the rotary handle connecting block 318; a U-shaped groove 3162 is arranged on the inner side surface of the coil straight edge pressing block 316, and a strip-shaped hole 3161 is arranged between the U-shaped groove 3162 and the upper top surface of the coil straight edge pressing block 316; the coil straight line side pressing block 316 is movably sleeved on a first step column 317 on the coil straight line side pressing block 316 from top to bottom through a strip hole 3161, so that an eccentric column 315 with steps is movably arranged in a U-shaped groove 3162, the turning plate 311 is connected with a rotary handle 314 through an eccentric column hanging hole 3111 and is connected on the first step column 317 exposed above the top end surface of the coil straight line side pressing block 316 in a penetrating way, a rotary handle locking nut 313 is screwed on a second step column 312 with threads above the rotary handle 314, the rotary handle 314 rotates to drive the eccentric column 315 with steps to rotate, thereby realizing that the eccentric column 315 with steps is close to or far away from the lower coil straight line section molding support angle iron crossbeam 106, and the eccentric column 315 with steps passes through the strip hole 3161 on the coil straight line side pressing block 316, and pushing the linear edge pressing block 316 of the coil to press the linear edge of the coil tightly or loosening the linear edge of the coil to shape and clamp the linear edge of the coil.

The upper coil straight line edge of the twist nose U-shaped coil is abutted against an angle iron groove of an upper coil straight line section forming supporting angle iron beam 105, the inner side surface of the top end of the right side of the upper coil straight line section forming supporting angle iron beam 105 is connected with an upper coil right turning plate type eccentric wheel clamping mechanism 304, an upper coil straight line edge 403 is clamped between the upper coil right turning plate type eccentric wheel clamping mechanism 304 and the upper coil straight line section forming supporting angle iron beam 105, an upper coil straight line edge is arranged on the top end surface of an upper coil tail forming supporting platform 102, an upper coil tail bending third positioning column connecting screw hole 121 and an upper coil tail bending fourth positioning column connecting screw hole 122 are respectively arranged on the top end surface of the upper coil tail forming supporting platform 102, an upper coil tail bending third positioning column 205 is connected on the upper coil tail bending third positioning column connecting screw hole 121, an upper coil tail bending fourth positioning column 206 is connected on the upper coil tail bending fourth positioning column connecting screw hole 122, a threaded upright column is vertically arranged at the center of the top end face of the third positioning column 205 bent at the tail part of the upper-layer coil, another L-shaped limiting plate is inserted into the threaded upright column arranged at the center of the top end face of the fourth positioning column 206 bent at the tail part of the upper-layer coil, a U-shaped notch is formed in a horizontal plate of the other L-shaped limiting plate, the other L-shaped limiting plate is inserted into the threaded upright column arranged at the center of the top end face of the fourth positioning column 206 bent at the tail part of the upper-layer coil through the U-shaped notch, and a first bent edge 404 at the tail part of the upper-layer coil of a flat copper wire wave winding is arranged between a vertical plate of the other L-shaped limiting plate and the outer side face of the fourth positioning column 206 bent at the tail part of the upper-layer coil; the structure of a lower coil tail bending first positioning column 203, a lower coil tail bending second positioning column 204, an upper coil tail bending third positioning column 205, an upper coil tail bending fourth positioning column 206, a lower coil head lower bevel edge bending positioning column 201 and an upper coil head bevel edge bending positioning column 202 of the invention is completely the same, the lower parts of the lower coil tail bending third positioning column, the upper coil tail bending fourth positioning column 206, the lower coil head lower bevel edge bending positioning column 201 and the upper coil head bevel edge bending positioning column 202 are fixedly screwed with a workbench through lower bolts, a middle main body plays a role of a supporting point for bending coils, a stud at the upper part of the lower coil head is a sleeving supporting point of a bolt upright column penetrating through a through hole 7011 arranged at the front end of a handle of a roller type bending wrench 701, the roller type bending wrench 701 takes the stud at the upper part as a circle center, a roller 7013 at the lower part of the roller type bending wrench 701 is self-transmitting and rotates to realize the bending of the coils, the roller 7013 is movably sleeved with the lower part of an externally threaded core column 7012, the roller 7013 can not only self-transmitting, and the lifting device can flexibly lift, overcomes the height change of the working table, realizes the adaptive bending of the coil, and protects the coil at the bending position from being damaged.

A method for forming the tail part of a flat copper wire wave winding with a small span, a large cross section and a small end extending twist nose comprises a tooling base 1, a U-shaped coil with the twist nose, a roller type bending wrench 701 and an L-shaped limiting plate 601, wherein a U-shaped notch is formed in a horizontal plate of the L-shaped limiting plate 601, a bolt upright post cross-connecting through hole 7011 is formed in the front end of a handle of the roller type bending wrench 701, a wrench handle at the rear side of the bolt upright post cross-connecting through hole 7011 is provided with a core column connecting screw hole with internal threads, a core column 7012 with external threads is connected in the core column connecting screw hole with the internal threads, a locking nut with the external threads is arranged between the top end of the core column 7012 with the external threads and the top end face of the wrench handle, and a roller 7013 is movably sleeved at the lower end of the core column 7012 with the external threads; an upper coil head forming support platform 101 and an upper coil tail forming support platform 102 are respectively arranged on the rear side of the top end face of the tooling base 1, a lower coil head forming support platform 103 and a lower coil tail forming support platform 104 are respectively arranged on the front side of the top end face of the tooling base 1, the height of the top end face of the upper coil head forming support platform 101 is the same as that of the top end face of the upper coil tail forming support platform 102, the height of the top end face of the lower coil head forming support platform 103 is the same as that of the top end face of the lower coil tail forming support platform 104, and the height of the top end face of the upper coil head forming support platform 101 is lower than that of the top end face of the lower coil head forming support platform 103; an upper-layer coil straight-line section forming support angle iron beam 105 is arranged between the top end surface of the upper-layer coil head forming support table 101 and the top end surface of the upper-layer coil tail forming support table 102, and a lower-layer coil straight-line section forming support angle iron beam 106 is arranged between the top end surface of the lower-layer coil head forming support table 103 and the top end surface of the lower-layer coil tail forming support table 104; a lower coil tail bending first positioning column connecting screw hole 119 and a lower coil tail bending second positioning column connecting screw hole 120 are respectively arranged on the top end surface of the lower coil tail forming support table 104; a third positioning column connecting screw hole 121 bent at the tail part of the upper coil and a fourth positioning column connecting screw hole 122 bent at the tail part of the upper coil are respectively arranged on the top end surface of the upper coil tail part forming support table 102; a right front turning plate hinge seat 115 is arranged at the upper end of the right part of the lower coil straight-line segment molding supporting angle iron cross beam 106, and a lower coil right turning plate type eccentric wheel clamping mechanism 302 is hinged on the right front turning plate hinge seat 115; the lower coil right turning plate type eccentric wheel clamping mechanism 302 is formed by combining a turning plate 311, an eccentric column 315 with steps, a coil straight line edge pressing block 316 and a rotating handle 314; the turning plate 311 is hinged on a right front turning plate hinge seat 115 on the lower coil straight line section forming support angle iron beam 106 through a pair of hinge tongues 3112 on the turning plate 311, and an eccentric column hanging hole 3111 is formed on the turning plate 311; a first step column 317 is eccentrically and fixedly arranged on the top end surface of the stepped eccentric column 315, a rotary handle connecting block 318 is fixedly connected on the top end surface of the first step column 317, and a second step column 312 with threads is fixedly connected on the top end surface of the rotary handle connecting block 318; a U-shaped groove 3162 is arranged on the inner side surface of the coil straight edge pressing block 316, and a strip-shaped hole 3161 is arranged between the U-shaped groove 3162 and the upper top surface of the coil straight edge pressing block 316; the coil straight line side pressing block 316 is movably sleeved on a first step column 317 on the coil straight line side pressing block 316 from top to bottom through a long strip hole 3161, so that an eccentric column 315 with steps is movably arranged in a U-shaped groove 3162, the turning plate 311 penetrates through a hanging hole 3111 of the eccentric column to be connected on the first step column 317 exposed above the top end surface of the coil straight line side pressing block 316, a rotating handle 314 is connected on a rotating handle connecting block 318 penetrating above the top end surface of the turning plate 311, and a rotating handle locking nut 313 is screwed on a threaded second step column 312 above the rotating handle 314; the method is characterized by comprising the following steps:

firstly, turning down the right turning plate type eccentric wheel clamping mechanism 302 of the lower coil to the outer side of the linear edge 407 of the lower coil, rotating the rotating handle 314 to enable the stepped eccentric column 315 to backwards press the linear edge 407 of the lower coil, and clamping the linear edge 407 of the lower coil between the stepped eccentric column 315 and the linear edge forming support angle iron beam 106 of the lower coil;

secondly, bending a first positioning column connecting screw hole 119 at the tail part of the lower coil, connecting the tail part of the lower coil, bending a first positioning column 203, and enabling the tail end of the lower coil to be abutted against the inner side of the bent first positioning column 203 at the tail part of the lower coil;

thirdly, the drum type bending wrench 701 is sleeved on a vertical upright post on the top end face of the lower-layer coil tail bending first positioning post 203 through the bolt upright post penetrating through hole 7011, the drum type bending wrench 701 is rotated towards the right front direction, the drum 7013 rotates and moves along an arc line to extrude the tail of the lower-layer coil, and a first bending edge 408 of the tail of the lower-layer coil is formed in a bending mode;

fourthly, bending a second positioning column at the tail part of the lower coil to be connected with the screw hole 120, connecting a bent second positioning column 204 at the tail part of the lower coil, penetrating an L-shaped limiting plate 601 on a vertically arranged threaded upright column at the top end of the bent second positioning column 20 at the tail part of the lower coil through a U-shaped notch, and enabling the tail part of the lower coil to be arranged between a vertical plate of the L-shaped limiting plate 601 and the bent second positioning column 204 at the tail part of the lower coil;

fifthly, sleeving a roller type bending wrench 701 on a vertically arranged threaded upright column at the top end of the second positioning column 204 for bending the tail part of the lower coil, and enabling a roller 7013 on the roller type bending wrench 701 to abut against the outer side face of the tail part of the lower coil;

seventhly, rotating the roller type bending wrench 701 anticlockwise, rotating a roller 7013 along an arc line, extruding and bending the tail of the lower-layer coil, bending the second positioning column 204 at the tail of the lower-layer coil to be a supporting point in the right-rear direction, and bending to form a second bent edge 409 at the tail of the lower-layer coil;

according to the invention, the positioning columns are in threaded connection with the working table surface, so that the interference between the coil and the positioning columns in bending is overcome, and the positioning columns can be conveniently installed and detached according to an operation program.

Eighthly, turning down the right turning plate type eccentric wheel clamping mechanism 304 of the upper coil to the outer side of the straight edge 403 of the upper coil; the structure of the upper-layer coil right-turning plate type eccentric wheel clamping mechanism 304 is completely the same as that of the lower-layer coil right-turning plate type eccentric wheel clamping mechanism 302; rotating the rotating handle to enable the eccentric column with the step to extrude the linear edge 403 of the upper coil forwards, and clamping the linear edge 403 of the upper coil between the eccentric column with the step and the linear edge molding support angle iron beam 105 of the upper coil;

ninth, bending a third positioning column connecting screw hole 121 at the tail part of the upper coil, connecting the tail part of the upper coil, bending a third positioning column 205, and enabling the tail end of the upper coil to abut against the inner side of the bent third positioning column 205 at the tail part of the upper coil;

tenth, a roller type bending wrench 701 is sleeved on a vertical upright post on the top end face of the third positioning column 205 bent at the tail part of the upper coil through a bolt upright post penetrating through a through hole 7011, the roller type bending wrench 701 is rotated towards the right front direction, a roller 7013 rotates and moves along an arc line to extrude the tail part of the upper coil, and a first bending edge 404 at the tail part of the upper coil is formed in a bending mode;

step eleven, connecting an upper-layer coil tail bending fourth positioning column 206 on an upper-layer coil tail bending fourth positioning column connecting screw hole 122, penetrating an L-shaped limiting plate 601 onto a vertically arranged threaded upright column at the top end of the upper-layer coil tail bending fourth positioning column 206 through a U-shaped notch, and enabling the tail of the upper-layer coil to be arranged between a vertical plate of the L-shaped limiting plate 601 and the upper-layer coil tail bending fourth positioning column 206;

step ten, sleeving a roller type bending wrench 701 on a vertically arranged threaded upright column at the top end of the fourth positioning column 206 bent at the tail part of the upper coil, and enabling a roller 7013 on the roller type bending wrench 701 to abut against the outer side face of the tail part of the upper coil;

and a thirteenth step of rotating the drum type bending wrench 701 clockwise, rotating the drum 7013 along an arc line, extruding and bending the tail of the upper coil, bending the fourth positioning column 206, which is bent by the tail of the upper coil, to the right front direction as a supporting point, and bending to form a second bent edge 405 at the tail of the upper coil.

Claims

1. A small-span large-section small-end-stretching torsion-nose flat copper wire wave winding head forming tool comprises a tool base (1) and a splayed coil with a torsion-nose; the head of the splayed coil with the twisting nose is provided with the twisting nose (401), and the twisting nose (401) is provided with the twisting nose hole (410); an upper coil head forming support table (101) and an upper coil tail forming support table (102) are respectively arranged on the rear side of the top end face of the tooling base (1), a lower coil head forming support table (103) and a lower coil tail forming support table (104) are respectively arranged on the front side of the top end face of the tooling base (1), the height of the top end face of the upper coil head forming support table (101) is the same as that of the top end face of the upper coil tail forming support table (102), the height of the top end face of the lower coil head forming support table (103) is the same as that of the top end face of the lower coil tail forming support table (104), and the height of the top end face of the upper coil head forming support table (101) is lower than that of the lower coil head forming support table (103); an upper coil straight line section forming supporting angle iron beam (105) is arranged between the top end surface of an upper coil head forming supporting platform (101) and the top end surface of an upper coil tail forming supporting platform (102), a lower coil straight line section forming supporting angle iron beam (106) is arranged between the top end surface of a lower coil head forming supporting platform (103) and the top end surface of a lower coil tail forming supporting platform (104), the upper coil straight line section forming supporting angle iron beam is characterized in that a twisted nose inserting groove rear vertical plate (107) is arranged on the left front side of the top end surface of the upper coil head forming supporting platform (101), a twisted nose inserting groove front vertical plate (108) is arranged on the left rear side of the top end surface of the lower coil head forming supporting platform (103), a twisted nose inserting groove (109) is formed between the twisted nose inserting groove rear vertical plate (107) and the twisted nose inserting groove front vertical plate (108), and a twisted nose inserting groove rear vertical plate (107) is arranged on the twisted nose inserting groove rear vertical plate (107), a rear part through hole (110) of a twist nose positioning pin is arranged, a front part through hole (111) of the twist nose positioning pin is arranged on a front part vertical plate (108) of the twist nose inserting groove, an upper layer coil head part inclined edge bending positioning column connecting screw hole (118) is arranged on the top end surface of an upper layer coil head part forming supporting platform (101) between a rear part vertical plate (107) of the twist nose inserting groove and an upper layer coil straight line part forming supporting angle iron cross beam (105), an upper layer coil head part inclined edge bending positioning column (202) is screwed on the upper layer coil head part inclined edge bending positioning column connecting screw hole (118), a lower layer coil head part inclined edge positioning column connecting screw hole (113) is arranged on the top end surface of a lower layer coil head part forming supporting platform (103) between the front part vertical plate (108) of the twist nose inserting groove and a lower layer coil straight line part forming supporting angle iron cross beam (106), a lower layer coil head part inclined edge bending positioning column connecting screw hole (113) is arranged on the lower layer coil head part inclined edge bending positioning column connecting screw hole (113), a lower bevel edge bending positioning column (201) at the head part of the lower coil is screwed; a threaded upright post (112) for the outer end of a lower compression beam to be connected in a penetrating way is fixedly arranged on the top end face of a lower-layer coil head forming support table (103) on the front side of a vertical plate (108) at the front part of a twisted nose inserting groove, a bolt upright post is vertically arranged at the center of the top end face of a lower bevel edge bending positioning post (201) of the head part of a lower-layer coil, and another bolt upright post is vertically arranged at the center of the top end face of a bevel edge bending positioning post (202) of the head part of an upper-layer coil; a twist nose (401) of the splayed coil with the twist nose is inserted into a twist nose insertion groove (109), and a twist nose limiting pin (501) is connected between a rear part through hole (110) of the twist nose positioning pin and a front part through hole (111) of the twist nose positioning pin in a penetrating way; the upper-layer coil head of the splayed coil with the twisting nose is abutted to the rear side surface of the bevel edge bending positioning column (202) of the upper-layer coil head; the lower-layer coil head of the splayed coil with the twist nose is abutted against the front side face of a lower bevel edge bending positioning column (201) of the lower-layer coil head, a lower pressing beam (801) is movably connected between a threaded upright column (112) and a bolt upright column on the lower bevel edge bending positioning column (201) of the lower-layer coil head in a penetrating manner, the lower pressing beam (801) is arranged right above the lower-layer coil head of the splayed coil with the twist nose, a lower pressing nut (901) is screwed at the top end of the threaded upright column (112), the top end of the bolt upright column of the lower bevel edge bending positioning column (201) of the lower-layer coil head is screwed with another lower pressing nut, and the lower pressing nut (901) and the other lower pressing nut are all in pressure joint with the top end face of the lower pressing beam (801); a roller type bending wrench (701) is movably sleeved at the top end of a bolt upright post of a lower-layer coil head lower bevel edge bending positioning post (201) above the other lower pressing nut, a bolt upright post cross-connecting through hole (7011) is arranged at the front end of the roller type bending wrench (701), a wrench handle at the rear side of the bolt upright post cross-connecting through hole (7011) is provided with a core post connecting screw hole with internal threads, a core post (7012) with external threads is screwed in the core post connecting screw hole with the internal threads, a locking nut with the core post (7012) with the external threads is arranged between the top end of the core post (7012) with the external threads and the top end surface of the wrench handle, a roller (7013) is movably sleeved at the lower end of the core post (7012) with the external threads, the roller type bending wrench (701) is movably sleeved at the top end of the bolt upright post of the lower bevel edge bending positioning post (201) at the lower-layer coil head through the bolt upright post cross-connecting through hole (7011), the roller (7013) is connected with the front side surface of the lower coil head of the splayed coil with the twisting nose in an abutting mode; the top end of another bolt upright post on the head part bevel edge bending positioning column (202) of the upper coil is movably sleeved with a drum-type bending spanner (701), the front end of a handle of the drum-type bending spanner (701) is provided with a bolt upright post cross-connecting through hole (7011), a wrench handle at the rear side of the bolt upright post cross-connecting through hole (7011) is provided with a core post connecting screw hole with internal threads, a core post (7012) with external threads is connected in the core post connecting screw hole with the internal threads, a locking nut with the external thread core post (7012) is arranged between the top end of the core post (7012) with the external threads and the top end surface of the wrench handle, the lower end of the core post (7012) with the external threads is movably sleeved with a drum (7013), the drum-type bending spanner (701) is movably sleeved at the top end of the bolt upright post of the head part bevel edge bending positioning column (202) of the upper coil through the bolt upright post cross-connecting through the bolt upright post (7011), the roller (7013) is abutted against the rear side of the upper coil head of the splayed coil with the twist nose.

2. The tooling for molding the head of the flat copper wire wave winding with the small span, the large section, the small end extension twisting lug according to claim 1 is characterized in that the lower bottom surface (8011) of the lower pressing beam (801) is an inclined surface, and the inclination angle of the lower bottom surface (8011) is the same as the inclination angle of the upper top surface of the lower coil of the splayed coil with the twisting lug.