Annular Conductor Inserting Device for Armature Manufacturing
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Solution Overview
Problem
Conventional methods for manufacturing armatures with distributed winding types face complications in equipment cost and production efficiency due to complex coil retaining devices and require the use of different types of annular conductors with specific insertion orientations, leading to reduced productivity.
Innovation Solution
A method utilizing a simple annular conductor inserting device with a retention guide portion and engagement portion to arrange and insert annular conductors into slots, allowing for a combination of simple and overlap arrangement steps to improve production efficiency, enabling the formation of armatures with reduced coil end interference and enhanced automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a coil retaining device with two movable main retaining portions having semi-cylindrical shapes is used to retain annular conductors in lap winding shape, then coil end interference is reduced and size reduction is achieved, but the configuration becomes complicated, equipment cost increases, and takt time increases reducing production efficiency
Solution Approach 1:
The coil retaining device is divided into a fixed retaining portion and a movable retaining portion. The fixed portion provides stable support while the movable portion enables the necessary motion for inserting annular conductors. This segmentation simplifies the overall device structure compared to having two movable semi-cylindrical portions, while still achieving the lap winding configuration that reduces coil end interference and armature size.
2Device complexity
If annular conductors are arranged in a coil retainer with multiple blades in cylindrical shape without integration, then device complexity is reduced, but specific annular conductors must be inserted in opposite inclination directions requiring complex manufacturing processes and reducing productivity
Solution Approach 1:
The retaining portion is designed to be movable, allowing the device to adapt its configuration dynamically during the insertion process. This dynamic capability enables all annular conductors to be inserted in a uniform direction without requiring separate handling of specific conductors, thereby simplifying the manufacturing process and improving productivity while maintaining a relatively simple device structure.
3Object-generated harmful factors
If conventional coil retaining devices are used to achieve lap winding configuration, then coil end interference is reduced, but takt time for inserting coils increases reducing production efficiency
Solution Approach 1:
The movable retaining portion acts as an intermediary mechanism that facilitates the insertion of annular conductors in a streamlined manner. It enables the lap winding configuration to be achieved without requiring complex multi-stage operations, thereby reducing the takt time for coil insertion while still effectively minimizing coil end interference through the volute-shaped arrangement.
4Shape
If annular conductors are arranged in inclined state in coil retainer, then lap winding configuration is achieved, but different insertion directions for different conductors are required complicating the manufacturing process
Solution Approach 1:
The movable retaining portion is designed to perform multiple functions: it holds annular conductors in the inclined position necessary for lap winding configuration, enables uniform insertion direction for all conductors, and facilitates the volute-shaped arrangement. This multi-functional design achieves the desired coil end shape while keeping the manufacturing process simple and unified.
Data Source
AI summary
An annular conductor retaining device has a retention guide portion formed by blades arranged in a cylindrical shape with gaps therebetween. An annular conductor is inserted into two of the gaps across a plurality of the blades. The next annular conductor is inserted into the gaps to partially overlap the previously arranged annular conductor. This step is repeated so that the annular conductors are arranged in a spiral shape in the retention guide portion. The retention guide portion and the inner circumferential part of the core are fitted to each other, and the gaps and the slots of the core are made to coincide with each other. A pusher is inserted into the inner circumferential part of the retention guide portion so that the annular conductors are caught on the pusher, to move them in the axial direction into the slots of the core, and thus become the coils.