Band-Shaped Coil Forming Apparatus with Variable-Depth Gripping Grooves
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Solution Overview
Problem
Existing coil forming methods for rotary electric machines fail to accurately wind band-shaped coils into a predetermined cylindrical wound state, leading to poor quality products, increased material consumption, extended manufacturing times, and higher energy usage, which negatively impacts the environment.
Innovation Solution
A coil forming apparatus and method utilizing a coil winding jig with comb-shaped grooves, a conveying mechanism with gripping grooves of varying depth, and guide members to pivotally convey and reform the band-shaped coil into an arc shape, ensuring precise alignment and winding without displacing straight portions, allowing for efficient use of recycled copper wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the band-shaped coil is wound on a coil winding jig using conventional methods, then the coil can be formed into a cylindrical wound state, but the straight portions may displace or misalign during winding, resulting in poor quality
Solution Approach 1:
A preliminary alignment member is inserted between adjacent straight portions to serve as an intermediary that maintains their relative positions. This alignment member acts as a mediator that prevents displacement during the winding process, ensuring that straight portions remain properly aligned when formed into the cylindrical wound state on the coil winding jig.
Solution Approach 2:
The alignment of straight portions is performed in advance before the actual winding process begins. The preliminary alignment member is positioned between adjacent straight portions prior to winding, ensuring that the alignment is established beforehand and maintained throughout the winding operation, thereby preventing misalignment during the forming process.
2Manufacturing precision
If the band-shaped coil is not properly reformed into an arc shape to follow the coil winding jig, then the winding process can proceed quickly, but the coil will not reach the specified wound state, leading to poor quality and increased material consumption
Solution Approach 1:
The band-shaped coil is reformed from a flat configuration into an arc shape that conforms to the cylindrical geometry of the coil winding jig. This curvature transformation ensures that the coil follows the outer circumference of the jig during winding, enabling it to achieve the specified cylindrical wound state with proper geometric conformity.
Solution Approach 2:
The physical parameters of the band-shaped coil are changed during the reforming process, specifically transforming its shape from a straight or flat configuration to an arc shape with appropriate curvature radius. This parameter change in the coil's geometric configuration enables it to properly follow the coil winding jig's outer circumference and achieve the desired wound state.
3Loss of substance
If poor quality coils are produced due to improper winding, then material consumption increases and resources are wasted, but the manufacturing process becomes less efficient
Solution Approach 1:
The alignment member provides feedback by maintaining the correct spacing and positioning of straight portions throughout the winding process. This feedback mechanism ensures that the coil is properly aligned and formed, preventing defects that would lead to material waste and rework, thereby improving both quality and manufacturing efficiency.
Data Source
AI summary
A coil forming apparatus for precisely reforming a band-shaped coil having straight portions and side ends, in an arc shape includes: a coil winding jig for inserting the straight portions into comb-shaped grooves thereof and winds; a coil conveying mechanism for pivotally conveying the band-shaped coil; and guide members for guiding the side ends, and inserts each of the straight portions into a respective one of the plurality of comb-shaped grooves, in which the coil conveying mechanism unit has a conveying rail and a conveyor, the conveyor has a plurality of gripping grooves for gripping a respective one of the plurality of straight portions, the plurality of gripping grooves having a coil abutting bottom surface of a depth according to an overlapping number of the plurality of straight portions which differs according to position in the conveying direction of the band-shaped coil.