Automated Coil Bending Tool for Dynamo Electric Machines
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Solution Overview
Problem
Existing methods for forming coil members in dynamo electric machines are inefficient due to the need for repetitive and sequential manual operations, which limits precision, speed, and versatility in bending electric conductors into various shapes.
Innovation Solution
An automated apparatus and method using a bending tool with programmable and precision movements, comprising a system of rotating members and motors to synchronize and coordinate the engagement members' positions and orientations, allowing for rapid and precise formation of coil members with various shapes, such as hairpins and undulated configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated bending tool with programmable movements is used, then manufacturing precision and productivity are improved, but device complexity increases
Solution Approach 1:
The bending tool is divided into multiple engagement members (first engagement member, second engagement member, third engagement member) that can independently engage and bend the electric conductor at different positions and orientations. This segmentation allows complex bending operations to be performed through coordinated simple actions of individual members, achieving high precision while managing device complexity through modular design.
Solution Approach 2:
The apparatus employs a dynamic control system where the engagement members can move relative to each other and to the conductor during the bending process. The control unit coordinates the movements of multiple engagement members in real-time, allowing the system to adapt to different coil shapes and bending requirements, thereby achieving high manufacturing precision through flexible, programmable motion rather than rigid fixed-position mechanisms.
2Adaptability or versatility
If multiple engagement members with coordinated movements are used, then versatility in forming various coil shapes is improved, but device complexity increases
Solution Approach 1:
The bending tool incorporates multiple engagement members that can perform various bending operations on the electric conductor. The first engagement member engages the conductor, the second engagement member bends it in a first direction, and the third engagement member bends it in a second direction perpendicular to the first. This multi-functional design allows a single apparatus to form various coil shapes including hairpins and undulated configurations, achieving versatility without requiring multiple separate devices.
Solution Approach 2:
The bending process follows a periodic sequence of operations: the engagement members advance to engage the conductor, perform bending movements in coordinated fashion, then retract and reset for the next cycle. This periodic action pattern allows the complex multi-member system to operate efficiently by repeating standardized sequences, managing device complexity through rhythmic, programmed operations rather than continuous complex coordination.
3Productivity
If rapid movements of bending tool are implemented, then productivity is improved, but manufacturing precision may deteriorate
Solution Approach 1:
The bending operations are performed in continuous coordinated motion without interruption. Multiple engagement members work simultaneously and sequentially in a continuous cycle, advancing the conductor through the bending process without stopping between operations. This continuous action maintains productivity while ensuring precision through uninterrupted, smoothly coordinated movements of all engagement members under programmable control.
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
The solution significantly reduces cycle time and enhances the ability to form a variety of coil shapes with high precision, improving the efficiency and versatility of the coil member formation process.
Implementation Method 1
Bending to form a coil member requires repetitive steps of feeding predetermined lengths of an electric conductor in alignment with a bending tool... During the feeding steps, a bending tool engages the electric conductor and performs predetermined movements to cause permanent bending into a required shape of the electric conductor.
Data Source
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AI summary
The invention relates to an apparatus and process for manufacturing coil members (20) to be inserted in the slots (21) of the core of a dynamo electric machine, the coil members (20) being formed by bending portions of an electric conductor (300) using at least a first engagement member (112). The apparatus comprises: a first member (23) that rotates around a first axis of rotation (17a); a second member (24) that rotates around a second axis of rotation (18a) positioned laterally with respect to the first axis of rotation (17a), wherein the second member (24) is supported by the first member (23); a third member (25) rotating around a central axis of rotation of the second member (24); wherein the third member (25) being supported by the second member (24). The first engagement member (112) being capable of engaging the conductor (300) against a contrast surface (192) to bend a portion of the conductor. The rotations of the first member (23) and of the second member (24) cause the at least a first engagement member (112) to move in a plane (P), whilst the rotation of the third member (25) causes the at least a first engagement member (112) to rotate in the plane (P). Preferably, the rotation of a fourth member (26) causes the at least a first engagement member (112) to rotate out of the plane (P).