Rotary Electric Machine Coil Segment Shaping and Assembly
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Solution Overview
Problem
Conventional coil segment shaping methods require multiple press dies for varying coil segment shapes, leading to complex management and reduced work efficiency, as each shape change necessitates die exchange and complicates the assembly process.
Innovation Solution
A manufacturing apparatus and method that continuously shapes and assembles coil segments based on control data, eliminating the need for die exchange and simplifying management by integrating a wire rod providing section, coil segment shaping section, and coil assembling section, allowing for efficient production of various coil shapes without stock management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple press dies are prepared for different coil segment shapes, then various coil segment shapes can be manufactured, but device complexity and management difficulty increase
Solution Approach 1:
A single press die is designed to perform multiple functions by forming different coil segment shapes through controlled bending operations. The press die includes a press surface that can form various shapes (U-shape, rectangular, etc.) by adjusting bending parameters, eliminating the need for multiple dedicated dies for different coil segment configurations.
Solution Approach 2:
The press die incorporates a movable pressing portion that can dynamically adjust its position and bending force during the forming process. This dynamic capability allows the same press die to produce various coil segment shapes by changing pressing parameters rather than requiring physical die exchanges, thereby reducing device complexity while maintaining shape versatility.
2Adaptability or versatility
If press dies are exchanged for different coil segment shapes, then shape variety is achieved, but productivity decreases due to die exchange time
Solution Approach 1:
The press die is designed as a universal tool that can form multiple coil segment shapes (U-shaped, rectangular, and other configurations) through a single die structure. This eliminates the need for die exchange operations when producing different coil segment shapes, thereby maintaining productivity while achieving shape variety.
Solution Approach 2:
The pressing operation can continue without interruption for producing different coil segment shapes using the same press die. The die structure allows continuous forming of various shapes by adjusting pressing parameters during the process, eliminating idle time associated with die exchange and maintaining continuous productive action.
3Adaptability or versatility
If coil segments with various shapes are assembled, then coil design flexibility is improved, but assembly process complexity increases
Solution Approach 1:
The press die forms various coil segment shapes that can be directly assembled into different coil configurations. By using a single press die to create multiple shape types (U-shaped segments, rectangular segments, etc.), the system achieves coil design flexibility while simplifying the assembly process, as segments can be sequentially assembled without complex management requirements.
4Adaptability or versatility
If multiple press dies are stocked for different shapes, then shape variety is achieved, but loss of substance increases due to inventory management
Solution Approach 1:
Instead of stocking multiple press dies for different coil segment shapes, a single universal press die is used that can form all required shapes. This eliminates the need for die inventory and associated management overhead, reducing loss of substance while maintaining the ability to produce various coil segment shapes on demand.
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 significantly improves work efficiency by enabling consistent shaping and assembly processes, reduces the complexity of managing multiple coil segment shapes, and allows for scalable manufacturing without the need for extensive die inventory, thus optimizing investment in equipment.
Implementation Method 1
a wire rod 6 cut into a predetermined length was sequentially bent into a three-dimensional shape by a first bending die, a second bending die and shaping rollers
Implementation Method 2
most of parameters of the coil segment, such as the curved shape of the linking portion of the coil segment and the width between the slot insertion portions of the coil segment, were defined by a die geometry (dimension and shape of press surface) of the press die or the press bending die
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3(a)~3(b)
AI summary
A manufacturing apparatus of an electrical rotating machine includes a coil segment shaping section for shaping a linear wire rod with a predetermined length into a coil segment with a predetermined shape consisting of a pair of slot insertion portions extending substantially in parallel with each other and a linking portion for coupling the pair of slot insertion portions, and a coil assembling section for assembling a coil by circularly arranging the coil segments shaped in the coil segment shaping section. The coil segment shaping section and the coil assembling section are constituted to continuously perform the shaping and the assembling of the coil segment in each coil segment unit, based on control data set depending on a coil to be fabricated.