Coil Segment Cutting Apparatus for Burr-Free Welding
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Solution Overview
Problem
In electrical rotating machines, the non-uniform cutting of coil segment end portions leads to burrs and uneven lengths, causing defects during welding, which can result in deterioration of mechanical and electrical properties over time.
Innovation Solution
A coil segment cutting method and apparatus that uses dual movable blades to alternately cut segment end portions, ensuring uniform lengths and preventing burrs by aligning apex positions, with the blades moving in opposite directions to support and cut each portion, thereby preventing metal flow-induced burrs and ensuring accurate alignment for high-quality welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single movable blade is used to cut segment end portions, then the cutting process is simple, but burrs occur due to metal flow in the downstream corner portion
Solution Approach 1:
The cutting process is segmented into two separate cutting actions: first cutting one segment end portion with a first movable blade, then cutting the other segment end portion with a second movable blade. This segmentation allows each blade to cut only one segment end portion, preventing metal flow-induced burrs that occur when a single blade attempts to cut both portions simultaneously.
Solution Approach 2:
Instead of cutting both segment end portions simultaneously or in sequence with a single blade, the invention uses two movable blades that move in opposite directions to cut each portion alternately. This inverted approach of using separate cutting tools for each portion eliminates the burr formation problem.
2Productivity
If cutting blades rotate from both sides to nip and simultaneously cut segment end portions, then cutting efficiency is improved, but the outer side of the peeled-off portion bulges causing burrs
Solution Approach 1:
The simultaneous cutting action is segmented into sequential cutting actions. Instead of both blades cutting at the same time, the first blade cuts one segment end portion, then the second blade cuts the other portion. This sequential approach maintains high efficiency while preventing the bulging and burr formation caused by simultaneous cutting forces.
Solution Approach 2:
The cutting process is made dynamic through sequential operation. The first movable blade performs its cutting action, then the second movable blade performs its cutting action. This dynamic sequential process allows each blade to work independently without interfering with the other, preventing metal flow-induced defects while maintaining productivity.
3Device complexity
If manual cutting is used, then device complexity is reduced, but cutting accuracy is lower compared to mechanical processes
Solution Approach 1:
The movable blades are designed to automatically perform the cutting action without manual intervention. The blades move along guide rails and are driven by a drive mechanism to cut the segment end portions with consistent precision. This self-service mechanical system eliminates the variability and lower accuracy associated with manual cutting.
Data Source
AI summary
A cutting unit has a support member having insertion holes, and a movable member having through holes connected thereto. The respective left sides of upper surfaces of the square through holes are first movable blades, and the respective right sides thereof are second movable blades. Firstly, the movable member 14 is moved to the right by a predetermined amount to cut peeled-off portions of segment end portions only, and then the movable member is moved to the left by a predetermined amount to cut peeled-off portions of the segment end portions only. Distal ends of the coil segments can be cut into a uniform length to enable high quality welding, through this process.