Preformed Coil Bending Body for Compact End Windings
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Solution Overview
Problem
The formation of end windings in high-power electric machines, such as those in wind turbines and tidal power plants, is challenging due to machine technology limitations, leading to bulging or spreading of coil windings when using preformed coils without plates, which results in suboptimal winding head shapes.
Innovation Solution
A manufacturing device utilizing a preformed body with a circular arc and chord portions guides the coil during bending, allowing for a 180° deflection to form compact end windings, reducing bulging and spreading, and enabling the use of a winding tool to pre-bend coils for improved shaping without additional effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a preformed body with only circular arc shape is used for coil bending, then the coil can be deflected, but bulging and spreading of windings occur during drawing
Solution Approach 1:
The preformed body is divided into two distinct portions: a first portion with a circular arc shape and a second portion with a chord shape. This segmentation allows different regions of the preformed body to serve different functions - the circular arc portion guides the coil bending while the chord portion prevents bulging during drawing, thereby resolving the contradiction between achieving coil deflection and maintaining winding shape precision.
Solution Approach 2:
Different portions of the preformed body are given different geometric qualities - the first portion has a circular arc curvature to enable coil bending, while the second portion has a straight chord configuration to prevent bulging. This local differentiation of geometric properties allows the preformed body to simultaneously achieve both coil deflection and prevent unwanted shape changes in different regions.
2Shape
If preformed plates are used to form end windings, then optimal winding head shape is achieved, but machine technology limitations prevent their use with very short winding heads
Solution Approach 1:
The preformed body with combined circular arc and chord portions serves multiple functions: it guides coil bending during forming and simultaneously prevents bulging during drawing, replacing the need for separate preformed plates. This multi-functional design makes it applicable to various winding head lengths, including very short ones where traditional preformed plates cannot be used.
3Productivity
If drawing is performed on preformed coils without proper guidance, then end windings are formed, but individual windings move away from each other
Solution Approach 1:
The preformed body is prepared in advance with both circular arc and chord portions configured to provide guidance during the subsequent drawing process. This preliminary configuration ensures that when drawing is performed, the coil windings are properly guided and constrained, preventing them from moving away from each other while still enabling efficient end winding formation.
Data Source
AI summary
A device for deflecting a coil includes a preformed body including a first portion configured as a circular arc to rest on the coil for bending, and a second portion adjoining the first portion and configured as a chord to rest on the coil for bending, wherein the first portion and the second portion are interchangeable.