Embedding Prefabricated Windings TRIZ Cases

Eccentric rolling shapes self-supporting motor coils to resolve centrifugal force limits, enabling longer conductors and higher power density.

A welding electrode establishes electrical conduction through paired conductor segments to join projecting ends using arc discharge.

A quadrangular stator coil installation jig segments restraint to allow intermediate winding portions to move freely during assembly.

Radial wire separation elements guide winding sections into stator gaps, reducing internal stress and preventing wire damage during insertion.

Peripheral drive discs rotate radial extraction blades to transfer entire windings in one operation, eliminating central shaft space constraints.

A circuit carrier guides conductor wires between pre-wound coil carriers, eliminating complex manual connections and reducing manufacturing errors.

A retaining apparatus constrains linear parts of a wave winding coil using pins to enable controlled deformation.

Segmented magnet coils with asymmetric ends prevent interference and reduce wire breakage during assembly.

An insertion apparatus assembles U-shaped conductors into a ring and supports the assembly using overlapping turn portions for slot placement.

Segmented pusher arms guide coil branches through forms to reduce mechanical resistance, preventing cover wedge displacement during high wire fill insertion.

A wave winding coil with variable slot pitch accommodates stator geometry during assembly.

Axial gaps between stator core ends and coil bridge portions enable refrigerant convection, resolving heat dissipation limits in high-output machines.

Segmented support lamellas guide conductive turns into laminated core grooves, preventing wire breakage from intertwining and misinsertion.

Segment conductors join axially using a positioning mediator that aligns joint surfaces and restricts radial displacement during pressing.

Segmented gripping elements compress and radially insert wires, resolving speed versus complexity trade-offs in electric motor manufacturing.

Stacked armature coils undergo controlled compression using a pressing die with a tapered surface to achieve precise fan-shaped geometry.

Bending winding segments tangentially across their length using compressive and frictional forces to eliminate projecting end portions.

A rotating former generates flat windings that transfer directly into stator grooves.

Transfer device rotates preformed electrical bar conductors for insertion into twisting device pockets.

Partial curing of form coils prevents resin drain-out and air pockets during vacuum pressure impregnation, ensuring superior insulation stability.

Segmented conductive coils with bared surfaces maintain contact within stator slots, eliminating weld stress and boosting slot filling rate.

A revolving conformator tool orients stator pin arms to create consistent gaps, resolving manual bending errors that obstruct oil circulation channels.

Radial interlacing tools reshape U-shaped preformed coils into concentric conductor leg arrays, resolving odd-strand slot fill issues in electrical machines.

A coil winding method for stator modules uses U-shaped conductor sections to simplify manufacturing.

Rotating U-shaped conductors while moving them radially inward aligns stator coil elements, preventing adjacent leg interference during high-density collection.

Toothed gripping elements hold rod sections in recesses during rotation, preventing axial displacement of the winding head.

Axial stacking of conductor terminals allows circumferential clamping, simplifying the welding process and reducing coil end height.

Segmented teeth engage rod sections to rotate and disengage multiple winding elements, reducing removal time.

A collecting receptacle with radially movable ribs positions concentric U-shaped conductors for axial insertion into electric machine stators.

Z-shaped angling and twisting of flat wires minimizes insulation damage while reducing copper usage in electric machine stators.

Radial stacking of phase half-windings shortens heads, improves temperature distribution, and increases electrical filling factors.

Radial connecting sections route coil wires outside stator poles, reducing ohmic losses and construction size.

An endless conveyor belt maintains constant spacing between undulation limbs during transfer, resolving inconsistencies caused by moving vehicle parts.

An assembly device inserts copper bars into electric machine rotor and stator elements using an alignment unit and slide mechanism.

A coil winding method for slotless stators forms polyphase windings on a mandrel, collapses them into a single-layer web, and wraps the assembly into a cylinder.

A pre-insertion device forms open annular winding structures from U-shaped conductor bars using a guide mechanism.

Crenellated winding segments enable simultaneous phase insertion, reducing mechanical force and improving air circulation in alternator stators.