Coil End Shaping Apparatus Managing Wire Expansion Errors
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Solution Overview
Problem
In rotary electric machines, the edgewise bent portions of lead wire portions are prone to increased dimensional errors and electric resistance due to uneven expansion during shaping, which affects the precision and efficiency of the coil end connections.
Innovation Solution
A coil end shaping apparatus and method that uses a combination of shaping dies to precisely shape edgewise bent portions by optimizing the expansion of the wire material, allowing for sequential shaping of both edgewise and flatwise bent portions while minimizing expansion errors and improving positional precision, using a movable die system with specific inclination angles and a pushing mechanism to prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a plurality of edgewise bent portions are collectively shaped by a pair of shaping dies, then the shaping process is efficient, but the wire material is expanded by a greater amount causing increased dimensional error and electric resistance
Solution Approach 1:
The patent divides the shaping process into two distinct stages: first shaping the edgewise bent portions on the base end side using a pair of shaping dies, and then shaping the edgewise bent portion closest to the free end side using one shaping die and a third shaping die. This segmentation allows control over wire material expansion at different locations, reducing dimensional errors while maintaining efficient shaping processes.
2Device complexity
If the free end portion is restrained during shaping of base end portions, then the shaping process is simplified, but the positional precision of the free end portion deteriorates
Solution Approach 1:
The patent employs a dynamic restraint mechanism where the third shaping die can be positioned to restrain the free end portion only when necessary for shaping the edgewise bent portion closest to the free end side. This dynamic approach allows the system to adapt between different shaping stages, maintaining both process simplicity and positional precision as needed.
3Loss of time
If multiple edgewise bent portions are shaped simultaneously, then the production time is reduced, but the uniformity of wire material expansion deteriorates
Solution Approach 1:
The patent applies different shaping configurations to different locations along the lead wire portion. The base end portions are shaped using a pair of shaping dies, while the free end portion is shaped using one shaping die and a third shaping die. This local differentiation ensures uniform wire material expansion characteristics are maintained at each location, addressing the non-uniform expansion issue while maintaining efficient production timing.
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 effectively reduces dimensional errors and electric resistance in edgewise bent portions, enhances the precision of lead wire connections, and shortens the shaping time for both edgewise and flatwise bent portions, thereby improving the overall efficiency and accuracy of coil end shaping.
Implementation Method 1
shape a plurality of edgewise bent portions that are bent in an edgewise direction by moving first and second shaping dies to approach each other
Data Source
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AI summary
A coil end shaping apparatus 20 shapes a plurality of edgewise bent portions e1 to e4 that are bent in the edgewise direction in a lead wire portion 11 extending from one end of a coil 10, and includes first and second shaping dies 21 and 22 capable of approaching each other to shape the edgewise bent portions e2 and e3 provided on the base end side with respect to the edgewise bent portion e4 that is the closest to the free end side among the plurality of edgewise bent portions e1 to e4, and a third shaping die 23 capable of cooperating with the second shaping die 22 to shape the edgewise bent portion e4 that is the closest to the free end side.