Coil Assembly Unit Manufacturing Method with Bent Portions
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Solution Overview
Problem
Conventional methods for manufacturing coil assembly units in rotary electric machines result in coil deformation and require larger, more expensive manufacturing devices due to the need for increased angles between coil wires, making it difficult to achieve precision and high-speed production, especially for longer axial lengths.
Innovation Solution
A method involving coil forming with bent portions at the ends of linear segments to allow for smaller weaving angles, followed by a weaving step where turn portions intersect and are compressed to minimize deformation, enabling faster and more precise coil assembly with smaller device sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional weaving methods are used with increased angles between coil wires to avoid interference, then coil wire deformation is reduced, but the size of manufacturing devices becomes larger and manufacturing cost increases
Solution Approach 1:
The coil wires are pre-formed with bent portions at both ends of linear portions before the weaving process. This preliminary shaping allows the turn portions to be positioned appropriately, enabling weaving at smaller angles between axis lines without causing interference between turn portions, thus avoiding the need for large-angle weaving devices
Solution Approach 2:
The invention changes the geometric parameters of the coil wire by introducing bent portions with specific angles. This parameter modification allows the coil wires to be woven at smaller angles between axis lines while maintaining adequate clearance between turn portions, thereby reducing manufacturing device size
2Manufacturing precision
If conventional weaving methods with larger rotation angles are used to avoid interference, then coil wire deformation is minimized, but manufacturing speed decreases and device size increases
Solution Approach 1:
By pre-forming the bent portions in the coil wires before weaving, the invention enables the weaving process to proceed at smaller rotation angles, which increases manufacturing speed while the subsequent compression step ensures high precision in the final coil assembly
3Device complexity
If coil wires are woven with smaller angles between axis lines, then manufacturing device size is reduced, but turn portions may interfere with each other
Solution Approach 1:
The bent portions are formed in advance on the coil wires, which pre-positions the turn portions to avoid interference during weaving at smaller angles between axis lines
Solution Approach 2:
The introduction of bent portions with specific angle parameters modifies the spatial arrangement of turn portions, allowing smaller weaving angles without causing interference between adjacent turn portions
Data Source
AI summary
A method of manufacturing a coil assembly unit comprises steps of coil forming, weaving, compressing steps. In the forming step, each coil wire is formed which provides linear portions and turn portions each connecting linear portions, during which bent portions are formed at both ends of each linear portion, the bent portions being bent so that mutually adjacent linear portions are deviated from each other. In the weaving step, the coil wires are mutually woven in turn, in which the turn portions intersect in turn. All the coil wires are subjected to the weaving step in turn to produce a woven coil assembly. In the compressing step, the woven coil assembly is compressed by compressing the woven coil so that each bent portion is deformed to be linear to allow the mutually adjacent linear portions to come closer to each other, thus producing the coil assembly unit.