Electric Machine Coil Bending for Compact Winding Heads
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Solution Overview
Problem
Existing methods for forming coils in high-power electrical machines, such as generators and motors, face challenges in achieving an optimal winding head shape without using forming plates, leading to bulging and spreading of coil windings, especially for coils with short winding heads.
Innovation Solution
A manufacturing device and method using a shaped body with a first section representing a circular arc and a second section representing a circular chord to guide the coil during bending, allowing for a 180° deflection and forming a winding head, with specific angular dimensions to prevent spreading and bulging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a circular shaped body is used to bend the coil, then the coil can be deflected, but a bulbous bulge occurs in the area where no coil is in contact
Solution Approach 1:
The shaped body is divided into three distinct sections: a first section with a first radius of curvature, a second section with a second radius of curvature, and a third section with a third radius of curvature. This segmentation allows each section to control a specific portion of the coil bending process, preventing bulging while achieving the desired winding head shape.
Solution Approach 2:
Different sections of the shaped body have different radii of curvature tailored to specific needs: the first section has a larger radius to guide the coil smoothly, the second section has a smaller radius to create the winding head, and the third section has a larger radius to prevent bulging. This local differentiation of geometric properties optimizes the bending process at each location.
2Shape
If forming plates are used to shape the winding head, then an optimal winding head shape can be achieved, but the process becomes complex and is not feasible for coils with very short winding heads
Solution Approach 1:
The invention extracts the essential forming function from complex forming plates and concentrates it into a simplified shaped body with three defined sections. This removes the need for additional forming plates and manual shaping operations, reducing device complexity while maintaining the ability to produce optimal winding head shapes.
Solution Approach 2:
The shaped body is designed to pre-form the coil into the desired configuration during the bending process itself. The three-section geometry is specifically configured to create the winding head shape and prevent bulging in advance, eliminating the need for subsequent forming operations or additional tools.
3Shape
If the coil is bent to form a winding head, then the coil can be inserted into stator slots, but the individual windings may become spaced apart
Solution Approach 1:
The third section of the shaped body, with its larger radius of curvature, acts as a cushioning zone that maintains winding tightness during the bending process. This section prevents the individual windings from spacing apart by providing a gradual transition that keeps the coil layers compressed together as the winding head is formed.
Data Source
Figure 1
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AI summary
A production device (11) is provided for producing a coil (7), the production device being used to deflect the coil (7), wherein a shaped body (9) is provided for the deflection, the shaped body (9) having a first portion (17), which constitutes a circular arc (19), and a second portion (18), which constitutes a circle chord (20). In order to be able to produce improved coils, both the first portion (17) and the second portion (18) are provided for the placing of the coil (7) in contact therewith.