Rotary Machine Coil Assembly Weaving Method
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Solution Overview
Problem
Existing methods for manufacturing coil assemblies of rotary electric machines require deformation steps that increase man-hours and risk damage to insulating films, complicating the weaving process.
Innovation Solution
A method involving a preparing step for coil wire segments with turn portions, followed by a locating and engaging process using forward transferring, rotating, and translating movements to weave the segments without the need for deformation, ensuring reliable and efficient engagement of turn portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a deforming step is conducted after the weaving step to obtain the final shape, then the coil wire segments can be shaped into the required form, but the number of man-hours increases and there is a risk of damage to the insulating film
Solution Approach 1:
The coil wire segments are pre-formed with a preliminary shape that includes straight portions and turn portions before the weaving step. This preliminary shaping is done during wire preparation rather than after weaving, eliminating the need for post-weaving deformation and reducing manufacturing time
Solution Approach 2:
Instead of deforming the coil wire segments after weaving to achieve the final shape, the invention inverts the sequence by pre-forming the wire segments with the necessary shape characteristics before weaving. The straight portions and turn portions are created in advance, and the weaving process itself arranges these pre-formed segments into the final coil assembly configuration
2Shape
If a deforming step is conducted after the weaving step to obtain the final shape, then the coil wire segments can be shaped into the required form, but damage may occur to the insulating film covering the surface
Solution Approach 1:
The coil wire segments are pre-formed with the required shape including straight portions and turn portions before the weaving step. This preliminary shaping is performed on the bare wire or with insulating film already in place, but without the mechanical stress of post-weaving deformation that could damage the insulating film
Solution Approach 2:
The invention reverses the conventional sequence by pre-forming the wire segments with the necessary geometric characteristics before weaving. This inversion eliminates the need for post-weaving deformation operations that pose a risk of damaging the insulating film, thereby maintaining reliability
3Ease of manufacture
If the weaving step uses coil wire segments of triangular wave shapes, then the weaving can be performed, but additional deforming steps are required after weaving
Solution Approach 1:
The coil wire segments are pre-formed with straight portions and turn portions in a preliminary shaping step before weaving. This preliminary action provides the wire segments with the necessary geometric characteristics for direct weaving into the final coil assembly shape, eliminating the need for subsequent deforming steps and reducing overall process complexity
Solution Approach 2:
The invention changes the geometric parameters of the coil wire segments by pre-forming them with specific straight portion lengths and turn portion configurations. This parameter adjustment during wire preparation allows the segments to be directly woven into the final shape without requiring additional deformation operations, thereby simplifying the manufacturing process
Data Source
AI summary
A method of manufacturing a coil assembly of a rotary electric machine is disclosed wherein first and second coil wire segments are located on an axis direction in opposition to each other to allow first turn portions of the first and second coil wire segments to intersect with each other (in locating step). Engaging movement, composed of a forward transferring movement, a rotating movement and a translating movement, is conducted on the second coil wire segment with respect to the first coil wire segment to allow the first turn portion of the second coil wire segment to engage a second turn portion of the first coil wire segment (first engaging step). Conducting the engaging movement allows to engage a third turn portion of the first coil wire segment (second engaging step).