Coil Segment Forming with Adjustable Press Jigs for Shape Changeovers
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Solution Overview
Problem
Conventional coil segment forming methods require multiple press dies with fixed geometries, leading to complex management, increased costs, and reduced efficiency due to die exchanges and prolonged shaping times, especially when producing coil segments with varying shapes.
Innovation Solution
A coil segment forming apparatus that adjusts the positions of press jigs based on set moving amounts for each coil segment shape, eliminating the need for die exchanges and allowing seamless transitions between forming processes without changing dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple press dies with fixed geometries are used to form different coil segment shapes, then various coil segment shapes can be produced, but device complexity and management difficulty increase
Solution Approach 1:
A single press die is designed to perform multiple functions by forming both the U-shaped linking portion and the crank-shaped step portion. The press die includes a first pressing surface for forming the U-shape and a second pressing surface for forming the step portion, eliminating the need for multiple separate press dies while maintaining the ability to produce various coil segment shapes.
Solution Approach 2:
The patent combines the functions of multiple press dies into a single integrated press die structure. The first and second pressing surfaces are integrated into one press die, allowing sequential formation of different features (U-shape and step portion) without die exchanges, thereby reducing device complexity and management burden.
2Adaptability or versatility
If press dies are exchanged to change coil segment shapes, then different shapes can be formed, but productivity decreases due to die exchange time
Solution Approach 1:
The single press die is configured to perform multiple forming operations sequentially without requiring die exchanges. By integrating both the first pressing surface for U-shape formation and the second pressing surface for step portion formation into one die, the system eliminates downtime associated with die changes while maintaining shape versatility.
Solution Approach 2:
The patent enables continuous forming operations by using a single press die that can sequentially create different features of the coil segment. The process maintains continuous useful action by eliminating interruptions for die exchanges, thereby improving productivity while still allowing formation of various coil segment shapes.
3Adaptability or versatility
If multiple press dies are prepared for different coil segment shapes, then various shapes can be produced, but manufacturing costs increase
Solution Approach 1:
The patent reduces manufacturing costs by designing a single universal press die that can produce multiple coil segment shapes. This eliminates the need to manufacture, maintain, and manage multiple specialized press dies, thereby reducing overall manufacturing expenses while preserving the capability to produce various coil segment configurations.
Solution Approach 2:
By merging the functions of multiple press dies into a single integrated die structure, the patent reduces the total number of components that need to be manufactured and maintained. This consolidation lowers manufacturing costs while still enabling production of diverse coil segment shapes through sequential pressing operations.
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
This approach reduces manufacturing costs, minimizes downtime, simplifies management, and enhances efficiency by enabling the production of coil segments with various shapes, while ensuring the production of coil segments with various shapes.
Implementation Method 1
pinch and press the linking portion (17a) of the first bent body (17)
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3
AI summary
A coil segment forming apparatus, a coil segment forming method and a manufacturing apparatus of an electrical rotating machine, whereby coil segments with various kinds of shape can be formed without exchanging a press die, it is not necessary that a lot of coil segments of various kinds of shape are preliminarily formed and stocked, and a transitional time between different shape-forming processes can be reduced is provided. The coil segment forming apparatus includes a second bending section for bending a first bent body consisting of a pair of slot insertion portions that are substantially parallel to each other and a linking portion for connecting the pair of slot insertion portions formed in the same plane. The bending of the first bent body is carried out in a plane perpendicular to the aforementioned same plane. The second bending section has a plurality of pairs of press jigs arranged to oppose to each other in directions intersecting with the aforementioned same plane for pinching and pressing the linking portion, and a plurality of drive mechanisms for moving respectively the plurality of pairs of press jigs in directions intersecting with the aforementioned same plane based on moving amounts respectively set depending on forming conditions of the coil segment to be formed.