Coil End Shaping Apparatus with Clearance Die for Wire Elongation Control
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Solution Overview
Problem
Existing coil shaping methods for rotary electric machines result in increased dimensional errors and electric resistance due to uneven bending of lead wire portions, particularly when bent in directions orthogonal to their cross-section, leading to elongation and interference issues.
Innovation Solution
A coil end shaping apparatus using a pair of shaping dies that come close to and away from each other, with one die featuring a clearance portion to prevent restraint of the lead wire portion on the free end side, allowing precise shaping of bent portions with one portion bent opposite to the others, thereby minimizing elongation and dimensional errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If multiple flatwise bent portions are collectively shaped by a pair of shaping dies, then the lead wire portion can be formed with bent portions in opposite directions for size reduction and interference suppression, but the wire material is elongated by a greater amount in bent portions on the base end side, causing increased dimensional error and electric resistance
Solution Approach 1:
The shaping process is divided into two distinct stages: first shaping the bent portion on the base end side, then shaping the bent portion on the free end side. This segmentation allows each bent portion to be shaped independently with appropriate die clearance, preventing excessive elongation and dimensional errors that would occur if all bent portions were shaped simultaneously.
Solution Approach 2:
The bent portion on the base end side is shaped first before shaping the bent portion on the free end side. This preliminary action ensures that the base end bent portion is formed with proper clearance while the wire is still relatively stable, preventing excessive elongation before subsequent bending operations.
2Shape
If multiple flatwise bent portions are collectively shaped by a pair of shaping dies, then the lead wire portion can be formed with bent portions in opposite directions, but the electric resistance increases due to greater elongation in bent portions on the base end side
Solution Approach 1:
The shaping process is divided into two distinct stages: first shaping the bent portion on the base end side, then shaping the bent portion on the free end side. This segmentation allows each bent portion to be shaped independently with appropriate die clearance, preventing excessive elongation and dimensional errors that would occur if all bent portions were shaped simultaneously.
Solution Approach 2:
The bent portion on the base end side is shaped first before shaping the bent portion on the free end side. This preliminary action ensures that the base end bent portion is formed with proper clearance while the wire is still relatively stable, preventing excessive elongation before subsequent bending 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
The apparatus collectively and precisely shapes multiple bent portions in the lead wire portion, reducing elongation and electric resistance, and improving the precision of the free end portion's position relative to the coil, enabling efficient size reduction and interference suppression.
Implementation Method 1
shape the at least two first bent portions by bringing close to each other to bend the lead wire portion
Data Source
AI summary
A coil end shaping apparatus shapes three flatwise bent portions f1 to f3 in a lead wire portion extending from one end of a coil by bringing first and second shaping dies close to each other such that one of the flatwise bent portions is bent in the direction that is opposite to the direction in which the rest are bent. The second shaping die, which is a movable die, has an clearance portion that prevents a portion of the lead wire portion to be bent along the flatwise direction on the side closest to the free end from being restrained by not contacting the lead wire portion while the flatwise bent portions on the base end side with respect to the flatwise bent portion on the side closest to the free end, of the three flatwise bent portions, are shaped in the lead wire portion.