Hairpin coil forming apparatus

Abstract

A hairpin coil forming apparatus configured to 3D-form a head portion of a 2D-formed I-shaped coil material, the hairpin coil forming apparatus includes a frame, a first mold disposed on a first side of the frame to form the head portion of the coil material into a predetermined shape, a second mold disposed on a second side of the frame to secondarily form the head portion of the pre-formed coil firstly formed by the first mold, a first coil transfer unit disposed in a process work area to transfer the coil material to the first mold, and a second coil transfer unit disposed on the frame to transfer the pre-formed coil from the first mold to the second mold.

What is claimed is: 
     
         1 . A hairpin coil forming apparatus configured to 3D-form a head portion of a 2D-formed I-shaped coil material, the hairpin coil forming apparatus comprising:
 a frame;   a first mold disposed on a first side of the frame to form the head portion of the coil material into a predetermined shape;   a second mold disposed on a second side of the frame to secondarily form the head portion of the pre-formed coil firstly formed by the first mold;   a first coil transfer unit disposed in a process work area to transfer the coil material to the first mold; and   a second coil transfer unit disposed on the frame to transfer the pre-formed coil from the first mold to the second mold.   
     
     
         2 . The hairpin coil forming apparatus of  claim 1 , wherein the first mold comprises:
 a first lower holder fixed to the frame;   a first lower die disposed in the first lower holder;   a first upper holder which is disposed to be movable in a vertical direction by operation of a first driver on a first mount block disposed on the first lower holder; and   a first upper die disposed in the first upper holder at a position corresponding to the first lower die.   
     
     
         3 . The hairpin coil forming apparatus of  claim 2 ,
 wherein the first lower die includes a pair of first lower forming steels which are fixed to the first lower holder, and   wherein the first upper die includes a pair of first upper forming steels that are fixed to the first upper holder.   
     
     
         4 . The hairpin coil forming apparatus of  claim 2 , wherein the first mold further comprises a first coil guider disposed on the first lower holder. 
     
     
         5 . The hairpin coil forming apparatus of  claim 4 , wherein the first mold further comprises a head portion clamper disposed on the first upper die to clamp the head portion of the coil material disposed on the first lower die. 
     
     
         6 . The hairpin coil forming apparatus of  claim 4 , wherein the first coil guider comprises a pair of first guide blocks fixed at a predetermined interval to the first lower holder to guide the leg portion of the coil material. 
     
     
         7 . The hairpin coil forming apparatus of  claim 5 , wherein the head portion clamper comprises at least one head portion clamping block disposed on the first upper die, elastically supported by a spring and movable in an up and down direction. 
     
     
         8 . The hairpin coil forming apparatus of  claim 7 , wherein the at least one head portion clamping block is disposed on a guide rod fixed to the inside of the first upper die to be movable in the vertical direction by a predetermined stroke. 
     
     
         9 . The hairpin coil forming apparatus of  claim 1 , wherein the second mold comprises:
 a second lower holder fixed to the frame;   a second lower die disposed in the second lower holder;   a second upper holder disposed to be movable in the vertical direction by operation of a second driver on a second mount block disposed on the second lower holder; and   a second upper die disposed in the second upper holder at a position corresponding to the second lower die.   
     
     
         10 . The hairpin coil forming apparatus of  claim 8 ,
 wherein the second lower die includes a pair of second lower forming steels which are fixed to the second lower holder, and   wherein the second upper die includes a pair of second upper forming steels fixed to the second upper holder.   
     
     
         11 . The hairpin coil forming apparatus of  claim 8 , wherein the second mold further comprises a second coil guider disposed on the second lower holder. 
     
     
         12 . The hairpin coil forming apparatus of  claim 10 , wherein the second mold further comprises a leg portion clamper which is disposed vertically movably on the second upper holder to clamp the leg portion of the pre-formed coil disposed on the second coil guider. 
     
     
         13 . The hairpin coil forming apparatus of  claim 11 , wherein the second coil guider comprises a pair of second guide blocks fixed at a predetermined interval to the second lower holder to guide the leg portion of the pre-formed coil. 
     
     
         14 . The hairpin coil forming apparatus of  claim 12 , wherein the leg portion clamper comprises:
 a leg portion clamping block which is disposed to move in the vertical direction by operation of a clamp cylinder disposed in the second upper holder; and   a leg pusher that extends protrudingly from the lower portion of the leg portion clamping block to press the leg portion between the second guide blocks.   
     
     
         15 . The hairpin coil forming apparatus of  claim 1 , wherein the first coil transfer unit comprises:
 a first horizontal moving member which is disposed to move in the horizontal direction by operation of a first actuator at a position corresponding to the first mold;   a first vertical moving member disposed in the first horizontal moving member to be configured to move in the vertical direction by operation of a second actuator; and   a first coil gripper disposed on the first vertical moving member to grip and un-grip the coil material by operation of a first gripping cylinder.   
     
     
         16 . The hairpin coil forming apparatus of  claim 15 , wherein the first horizontal moving member  63  is slidably connected to a first guide device disposed on a base plate along the horizontal direction. 
     
     
         17 . The hairpin coil forming apparatus of  claim 1 , wherein the second coil transfer unit comprises:
 a second horizontal moving member which is disposed to move in the horizontal direction by operation of a third actuator along the section between the first mold and the second mold;   a second vertical moving member disposed in the second horizontal moving member to be configured to move in the vertical direction by operation of a fourth actuator; and   a second coil gripper disposed on the second vertical moving member to grip and un-grip the pre-formed coil by operation of a second gripping cylinder.   
     
     
         18 . The hairpin coil forming apparatus of  claim 17 , wherein the second coil transfer unit further comprises a turning cylinder disposed on the second vertical moving member and connected to the second coil gripper. 
     
     
         19 . The hairpin coil forming apparatus of  claim 17 , wherein second horizontal moving member is slidably connected to a third guide device disposed on the frame  10  along the horizontal direction and moved in the horizontal direction along the third guide device.