Cam-Controlled Wire Stripping for Clean Coil Winding Welds
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for removing the insulating layer from wires used in electric machine coil windings, such as those employed in the hairpin process, result in poor quality and contamination due to the generation of small chips during milling, which can lead to defects in weld formation.
Innovation Solution
A device and method utilizing a slide arrangement with cutting and counter-bearing slides controlled by a cam disk, allowing for high-speed, high-quality stripping of the insulating layer by scraping, where the slides are moved in synchronization with the wire to ensure minimal relative movement and efficient removal of the insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If milling is used to remove the insulating layer, then the insulating layer can be removed, but small chips are generated causing poor quality and contamination
Solution Approach 1:
The patent replaces the milling mechanical system with a scraping mechanical system. Instead of using rotating milling cutters that generate chips, the invention employs scraping elements that slide along the wire surface to remove the insulating layer, thereby eliminating chip generation and improving surface quality
Solution Approach 2:
The patent changes the removal mechanism from cutting/milling to scraping. This parameter change in the removal method transforms the process from one that generates chips to one that produces minimal contamination, directly addressing the quality issue
2Productivity
If high-speed stripping is implemented, then productivity increases, but quality may deteriorate due to contamination
Solution Approach 1:
The scraping system enables high-speed operation without the chip generation problems of milling. The scraping elements are designed to maintain contact with the wire at high speeds while continuously removing insulation without contaminating the surface, thus achieving both high productivity and high quality
Solution Approach 2:
The invention extracts the harmful chip generation mechanism from the insulation removal process by using scraping instead of milling. This extraction of the problematic element (chip creation) allows high-speed operation without the associated quality degradation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables high-quality, high-speed stripping of the insulating layer with minimal contamination, achieving cycle times of one second or less and ensuring clean, defect-free welds in industrial mass production.
Implementation Method 1
a cam disk (36) with a recess or opening (62) through which the wire (14) can be guided by means of the wire guide (24), wherein the cam disk (36) is rotatable by means of a cam disk drive (38) and has a first control cam area (66.1) that is at least partially annular in shape for controlling and/or driving the movement of the at least one cutting slide (56) and a second control cam section (66.2) for controlling and/or driving the movement of the at least one counter-bearing slide (58)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
To enable process-reliable stripping of wires for the production of coil windings in large-scale industrial series production with fast cycle times and high quality, the invention provides a device (10) for removing an insulating layer (12) on a length section (18) of a wire (14) for forming a coil winding of an electrical machine, comprising: a wire guide (24) for guiding the wire (14) to be processed through it in a wire movement direction (26); a slide arrangement (34) with several slides (52.1-52.8), which are arranged around the wire (14) to be guided through the wire guide (24) and are radially displaceable back and forth relative to the wire (14) guided in the wire guide (24), wherein at least one cutting slide (56) with a cutting edge (60) for scraping off the insulation (12) and at least one counter-bearing slide (58) for holding the wire (14) during scraping are provided such that a cutting slide (56) and a counter-bearing slide (58) are opposite each other and are movable towards and away from each other, and a cam disk (36) with a recess or opening (62) through which the wire (14) can be guided by means of the wire guide (24), wherein the cam disk (36) is rotatable by means of a cam disk drive (38) and has a first control cam area (66) that is at least partially annular in shape.1) for controlling and/or driving the movement of the at least one cutting slide (56) and a second at least partially annular control cam area (66.2) for controlling and/or driving the movement of the at least one counter bearing slide (58).