Universal Coil Segment Forming Apparatus for Rotating Machines
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Solution Overview
Problem
Conventional coil segment forming methods require multiple press dies for varying coil shapes, leading to complex management, increased costs, and downtime due to die exchanges, as well as potential damage to the insulation layer of wire rods.
Innovation Solution
A coil segment forming apparatus using a first bending section with multiple jigs and drive mechanisms that adjust based on set moving amounts to form various coil shapes without the need for shape-specific press dies, allowing for efficient production of coil segments with different shapes without die exchanges and minimizing insulation layer damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple press dies with different shapes are prepared to form various coil segment shapes, then the ability to produce different coil shapes is improved, but the device complexity and management difficulty increase
Solution Approach 1:
A single press die is designed to perform multiple functions by forming both the linking portion and slot insertion portions in one pressing operation. The press die includes a pressing surface for forming the linking portion and side surfaces extending from the pressing surface to form the slot insertion portions, allowing one die to create various coil segment shapes by adjusting pressing parameters rather than requiring multiple specialized dies
Solution Approach 2:
The invention changes geometric parameters of the press die structure, specifically extending side surfaces from the pressing surface to form the slot insertion portions. By modifying parameters such as the extension length and angle of these side surfaces, different coil segment shapes can be produced using the same press die, reducing the need for multiple dies with fixed geometries
2Adaptability or versatility
If press dies are exchanged to form different coil segment shapes, then the versatility of production is improved, but the loss of time due to die exchange increases
Solution Approach 1:
The press die is designed as a universal tool that can form various coil segment shapes without requiring physical exchange. The single die structure includes configurable elements that allow it to adapt to different forming requirements, eliminating the time-consuming process of replacing dies between production runs
3Manufacturing precision
If a press die with fixed geometry is used to form coil segments, then the manufacturing precision of the coil segment shape is improved, but the object-affected harmful factors increase due to insulation layer damage
Solution Approach 1:
The invention introduces a flexible film between the press die and the wire rod during the forming process. This film prevents direct contact between the rigid press die surfaces and the wire rod insulation layer, thereby preventing scratches and damage while still allowing the press die to exert the necessary pressure to form the coil segment shape with high precision
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, eliminates downtime for die exchanges, simplifies management, and ensures efficient production of coil segments with various shapes while protecting the insulation layer, thereby enhancing working efficiency and reducing the need for stockpiling multiple coil shapes.
Implementation Method 1
a plurality of drive mechanisms for moving respectively the plurality of jigs on the same plane so that the wire rod is formed in the predetermined shape based on moving amounts respectively set depending on shape conditions of the coil segment to be formed
Implementation Method 2
a first bending section for bending in the same plane a linear wire rod into a predetermined shape 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
Data Source
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, and it is not necessary that a lot of coil segments of various kinds of shape are preliminarily formed and stocked is provided. The coil segment forming apparatus includes a first bending section for bending in the same plane a linear wire rod into a predetermined shape 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. The first bending section has a plurality of jigs arranged on the same plane for supporting the wire rod, and a plurality of drive mechanisms for moving respectively the plurality of jigs on the same plane so that the wire rod is formed in the predetermined shape based on moving amounts respectively set depending on shape conditions of the coil segment to be formed.