Electrodynamic Machine Coil Insulation via Preliminary Taping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for forming insulated coils for electrodynamic machines, such as AC induction motors, require costly and time-consuming hand taping of compound curved end portions and leads, which is prone to human error, and involve the temporary application and removal of sacrificial protective tape during the coil formation process.
Innovation Solution
Applying a multi-part resin impregnation system, including a catalytic material, to the coil bundle before its final formation steps, allowing for machine taping of the coil in a two-dimensional configuration and eliminating the need for temporary sacrificial tape, thus enabling machine wrapping of a larger percentage of the coil circumference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hand taping is used for compound curved end portions and leads, then insulation coverage is achieved, but manufacturing cost and time increase significantly
Solution Approach 1:
The coil is divided into different sections: straight sections that can be machine-taped and compound curved end portions that require hand taping. This segmentation allows machine automation for simple geometries while reserving manual operations for complex areas, resolving the contradiction between insulation coverage and manufacturing efficiency.
Solution Approach 2:
A temporary sacrificial protective tape layer is applied as an intermediary before the final insulation tape. This intermediate layer protects the wire insulation during high-pressure forming operations, enabling machine taping without damaging the wire, thus reducing both cost and time while maintaining reliability.
2Productivity
If machine taping is used for straight sections, then productivity increases, but compound curved end portions still require hand taping
Solution Approach 1:
The taping process is segmented into machine-taped straight sections and hand-taped curved end portions. This division allows the use of automated machinery for simple geometries, increasing productivity, while accepting manual operations for complex curved sections where machine access is difficult.
Solution Approach 2:
The coil is formed into its final three-dimensional configuration before the final insulation taping operation. This preliminary forming action creates accessible surfaces for machine taping on straight sections, enabling automated production while minimizing the need for complex hand taping operations.
3Reliability
If temporary sacrificial protective tape is applied before forming, then wire insulation is protected, but additional taping and removal steps are required
Solution Approach 1:
The sacrificial protective tape is applied preliminarily before the high-pressure forming operation to protect the wire insulation. This preliminary protection enables the subsequent machine taping operation to proceed without damaging the wire insulation, and the tape is later removed in a single batch operation rather than during each forming step, reducing total time loss.
Solution Approach 2:
A temporary sacrificial tape layer is used as a disposable protective element during forming operations. This cheap, short-lived component protects the valuable wire insulation during high-pressure forming, then is removed and discarded, enabling reliable machine taping without permanent damage to the coil structure.
4Reliability
If insulation tape is applied after final coil formation, then insulation integrity is maintained, but compound curved portions require expensive hand taping
Solution Approach 1:
The final insulation tape is applied preliminarily to the straight sections before the coil is formed into its final three-dimensional configuration. At this stage, the straight sections are accessible and flat, allowing economical machine taping. The coil is then formed, and only the compound curved end portions require subsequent hand taping, significantly reducing overall manufacturing expense while maintaining insulation integrity.
Solution Approach 2:
The taping operation is performed in a different dimensional state of the coil - on the two-dimensional flat loop configuration rather than the final three-dimensional formed shape. This dimensionality change makes straight sections accessible to machine taping tools, reducing manufacturing expense while the final forming operation creates the necessary three-dimensional geometry for motor operation.
Data Source
AI summary
A method for manufacturing electrodynamic machine conductive coils, such as alternating current induction motor stator coils. A continuous strand of insulation coated wire is formed into a generally planar elongated closed loop having a circumference and an outer surface. Thereafter a permanent insulation layer is applied to the closed loop outer surface, preferably by spiral wrapping insulating tape about the circumference of the closed loop with a tape wrapping machine. The insulating tape has a catalytic chemical compound including at least one part of a multi-part epoxy resin. The closed loop is shaped into a rigid conductive coil by application pressure, in order to conform the coil to a desired profile. Application of the permanent insulation layer to the closed loop prior to its final shaping enables machine insulation taping over a larger portion of the coil circumference and reduces need for slower and more expensive hand taping.