Annular Electrical Conductor Aligning Device with Radial Overlap
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Solution Overview
Problem
Existing methods for aligning U-shaped electrical conductors in an annular shape while overlapping in the circumferential direction are time-consuming and prone to interference, making it difficult to align the conductors efficiently.
Innovation Solution
An electrical conductor aligning device with holding sections arranged in an annular shape and a moving mechanism that allows the conductors to be aligned in intervals without overlapping initially, then moved radially to overlap, using a link mechanism to synchronize the movement of holding sections and reduce the need for multiple drive sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrical conductors are aligned in sequence by rotating the alignment ring pallet, then the conductors can be aligned in an annular shape while overlapping in the circumferential direction, but the alignment process becomes time-consuming
Solution Approach 1:
The invention prepares multiple electrical conductors in advance at different radial positions on the alignment ring pallet, so that when the pallet rotates, all conductors are positioned simultaneously rather than sequentially. This preliminary arrangement of conductors at predetermined positions enables parallel positioning instead of sequential alignment, resolving the contradiction between alignment precision and alignment speed.
2Manufacturing precision
If electrical conductors are aligned in order while overlapping in the circumferential direction, then the annular alignment is achieved, but interference occurs with already aligned conductors making alignment difficult
Solution Approach 1:
The invention introduces a radial dimension to the alignment process by positioning conductors at different radial distances from the center of the alignment ring pallet. This allows conductors to be arranged in concentric circles at different radii, preventing circumferential interference while maintaining the required overlapping alignment in the final product. The radial dimension provides an additional degree of freedom that eliminates the interference problem.
3Manufacturing precision
If multiple drive sources are provided for each holding section to move conductors radially, then precise control of each conductor is achieved, but the device complexity increases
Solution Approach 1:
The invention merges multiple drive functions into a single drive mechanism that simultaneously controls the radial movement of all holding sections. Instead of providing independent drive sources for each holding section, a unified drive system with a common drive shaft and synchronized mechanism is used, reducing the number of drive components while maintaining precise control over all conductors through coordinated motion.
Data Source
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AI summary
Provided are an electrical conductor aligning device that can, without mutual interference, easily, and in a short period of time, align a plurality of electrical conductors in an annular shape while overlapping in the peripheral direction. The coil element aligning device (1) is characterized by being provided with: holding sections (5), a slide mechanism (7, 7A) and a cylinder mechanism (9, 9). The aligning device (1) is further characterized by one leg of each coil element (10) being held by the plurality of holding sections, the plurality of coil elements being aligned in an annular shape at a spacing such that there is no overlapping in the peripheral direction, and then the plurality of holding sections being moved inwards in the radial direction by means of the slide mechanism and the cylinder mechanism, thereby aligning the plurality of coil elements in an annular shape while overlapping in the peripheral direction.