Coil Segment Forming with Pivoted Rotation for Layered Assembly
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Solution Overview
Problem
The existing coil forming methods require numerous lifting operations, significantly reducing the operational efficiency of the coil assembly process due to the need to lift all conductor segments to the inner circumference for each subsequent insertion, making the process cumbersome and time-consuming.
Innovation Solution
A coil forming apparatus that includes a holding member to pivot one slot insertion portion of each coil segment, allowing it to rotate without interference, and a mechanism to avoid interference with the second slot insertion portion during rotation, enabling efficient layer formation by overlapping coil segments without the need for extensive lifting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If all conductor segments are lifted to the inner circumference for each subsequent insertion, then the coil segments can be arranged in different layers, but the number of lifting operations increases significantly, reducing operational efficiency
Solution Approach 1:
The device divides the conductor segments into two independent receiving portions: a first receiving portion for the first slot insertion portion and a second receiving portion for the second slot insertion portion. This segmentation allows each portion to be handled independently, eliminating the need to lift all segments for each layer formation.
Solution Approach 2:
The device utilizes the radial dimension by positioning the first and second receiving portions at different radial locations. The outer member can rotate to move the second slot insertion portion radially inward to overlap with the first slot insertion portion, enabling layer formation without vertical lifting operations.
2Productivity
If the outer member rotates to move the second slot insertion portion closer to the inner member, then simultaneous layer formation is enabled, but interference may occur between the second slot insertion portion and the holding member
Solution Approach 1:
The holding member is designed to be movable rather than fixed. It can move to adjust its position and avoid interference with the second slot insertion portion during the rotation of the outer member, while still maintaining its function of holding the first slot insertion portion as a pivot.
Solution Approach 2:
The holding member proactively moves to a position where it will not interfere with the rotating second slot insertion portion before the interference can occur. This preliminary action prevents the harmful effect of interference while maintaining the rotational movement necessary for layer formation.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A plurality of housing grooves (11a) are formed at equal intervals in the circumferential direction on an outer peripheral edge of a circular block (11), and inner rods (13) are housed in these housing grooves (11a) and arranged to be movable radially along the radial directions. Outer rods (33) are provided to be movable radially along the radial directions, and respectively face the inner rods (13). Respective one slot insertion portions (18a) of coil segments (18) are inserted into gaps (39) between the inner rods (13) and insertion holes (19c) of the holding member (19). The respective other slot insertion portions (18b) are inserted into the gaps (41) between the outer rods (33). Thereafter, the whole outer rods (33) are rotated, and thereby the coil segments (18) are rotated around the slot insertion portions (18a) as pivots, the holding member (19) is lowered at a timing when the slot insertion portions (18b) abut the outer peripheral surface of the holding member (19), and the whole outer rods (33) are further rotated in a state where the holding member (19) does not interfere with the slot insertion portions (18b), thereby the coil segments come into close contact with one another. These configurations improve the efficiency of coil assembly operations.