Electrical Coil Forming Apparatus with Multi-Plane Spindle Assembly
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Solution Overview
Problem
Conventional electrical coil configurations for electrical machines result in excess material and length, leading to increased losses, ergonomic issues during installation, and potential damage to the insulating coating, due to their design with multiple bends and extended end turns.
Innovation Solution
A coil forming apparatus with a spindle assembly and drive system that forms electrical coils with specific bends and straight segments in different planes, reducing material usage and length, and facilitating efficient insertion into stator slots with reduced ergonomic strain.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional coil configurations with four bends are used, then the coil structure is simple to manufacture, but the straight portions and end turns have increased lengths resulting in excess material
Solution Approach 1:
The invention changes the geometric parameters of the coil by reducing the number of bends from four to two, and by optimizing the angles and positions of the remaining bends. This parameter optimization reduces the lengths of straight portions and end turns, thereby minimizing excess material while maintaining manufacturability through the structured forming apparatus
Solution Approach 2:
The invention positions bends in different planes (first plane for end turns, second plane for straight sections) rather than all in one plane. This dimensional arrangement optimizes space utilization and reduces material length requirements while keeping the manufacturing process manageable through the multi-plane forming capability of the apparatus
2Ease of manufacture
If conventional coil configurations with increased end turn lengths are used, then the coil structure is easier to form, but the end turns interfere with motor components such as brackets and baffles
Solution Approach 1:
The invention optimizes the parameters of end turns by reducing their length through fewer bends and by positioning them in a first plane that is different from the second plane of straight sections. This dimensional separation and length reduction eliminate interference with motor components like brackets and baffles while maintaining ease of formation through the structured apparatus
3Ease of manufacture
If conventional coil configurations with excess length are used, then the coil can be easily formed, but losses such as resistive losses and thermal losses increase during operation
Solution Approach 1:
The invention reduces energy losses by optimizing the geometric parameters of the coil - specifically reducing the total length of wire through fewer bends and optimized bend angles. The structured forming apparatus ensures that the reduced-length configuration is achieved with controlled precision, maintaining ease of formation while minimizing resistive and thermal losses during operation
4Ease of manufacture
If conventional coil configurations are used, then the standard insertion procedure can be followed, but the labor involved in pushing coils into stator slots increases leading to negative ergonomic effects
Solution Approach 1:
The invention improves ergonomic safety during installation by optimizing coil geometry parameters - reducing overall coil length and adjusting bend configurations. The structured forming apparatus produces coils with dimensions and shapes that facilitate easier insertion into stator slots, reducing the force and labor required while maintaining standardized insertion procedures
5Ease of manufacture
If conventional coil configurations are used, then the standard insertion procedure can be followed, but further pushing and bending of end turns is needed which may lead to cracking or damage to the insulating coating
Solution Approach 1:
The invention protects insulating coating integrity by optimizing coil geometric parameters - specifically reducing end turn lengths and adjusting bend positions and angles. The structured forming apparatus produces coils where the optimized geometry eliminates the need for additional pushing and bending during insertion, preventing cracking or damage to the insulating coating while following standardized procedures
Data Source
AI summary
A coil forming apparatus for forming an electrical coil from an electrical wire. The apparatus includes a frame and a spindle assembly coupled to the frame. The spindle assembly includes: a first arm coupled to the frame, wherein the first arm includes a first moveable bracket and a plurality of first moveable spindles coupled to the first moveable bracket and to the electrical wire in a first position. The spindle assembly further includes a second arm coupled to the frame, wherein the second arm has a second moveable bracket that includes a plurality of second moveable spindles coupled to the second moveable bracket and coupled to the electrical wire in the first position. The coil forming apparatus includes a drive system coupled to the first moveable bracket and the second moveable bracket. The drive system is configured to move the first moveable bracket and the second moveable bracket.