Motor Coil Winder Wire-Length Control for Slot-Specific Winding
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Solution Overview
Problem
Existing electric motor coil winding technologies result in material waste and increased costs due to inefficient wire length management, with cut wires often popping up and causing production interruptions, and existing solutions are cumbersome or costly to implement.
Innovation Solution
An electric motor coil winder with a rotary table, winding framework, flier part, gripping and cutting mechanisms, and a controller that adjusts wire length according to the motor's pulse, incorporating a cutting cover to prevent wire popping and optimize wire usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a fixed length wire is used for all slots, then the wire supply management is simplified, but material waste increases due to inability to tailor wire length to actual requirements
Solution Approach 1:
The wire supply system is made dynamically adjustable through a movable wire supply unit that can be positioned at different locations along the wire path. The controller dynamically calculates and adjusts the wire length based on the specific slot position and motor pulse requirements, enabling variable wire length cutting without complex mechanical reconfiguration. This resolves the contradiction by making the system adaptable (reducing waste) while maintaining operational simplicity.
Solution Approach 2:
The system changes the wire length parameter dynamically based on the slot position and motor pulse characteristics. The controller modifies the cutting length parameter for each wire according to the specific requirements of different slots, allowing optimal material utilization. This parameter adjustment capability reduces material waste while avoiding the need for complex physical system changes.
2Reliability
If no cutting cover is installed, then the device structure is simpler, but cut wires pop up and cause production interruptions and potential damage
Solution Approach 1:
The cutting cover is designed as a separate, removable component that can be easily installed and removed. It extracts the wire containment function from the main device structure, allowing it to be added or removed independently. This simple addition prevents wire scattering and production interruptions without significantly complicating the overall device structure.
Solution Approach 2:
The cutting cover acts as an intermediary element between the cutting mechanism and the surrounding environment. It contains the cut wire within a defined space, preventing it from scattering and causing problems. This simple intermediate structure effectively solves the wire scattering issue while adding minimal complexity to the system.
3Loss of substance
If wire length is not adjusted according to slot position, then the winding process is faster, but material costs increase due to excessive wire usage
Solution Approach 1:
The system automatically calculates and adjusts the wire length based on the slot position and motor pulse requirements without requiring manual intervention. The controller self-adjusts the cutting length parameter, and the movable wire supply unit self-positioned accordingly. This automated adaptation reduces material waste while maintaining efficient production speed, as no additional setup time is required.
4Adaptability or versatility
If the wire supply unit is fixed in position, then the device structure is simpler, but it cannot accommodate different wire length requirements for different slots
Solution Approach 1:
The wire supply unit is made movable along a defined path, allowing it to dynamically position itself according to the specific wire length requirements of different slots. This dynamic positioning capability enables the system to accommodate varying wire length needs while maintaining a relatively simple structure, as the movement is constrained to a straightforward linear or curved path rather than complex multi-axis motion.
Data Source
AI summary
An electric motor coil winder is provided. A cutting length of a wire used for an electric motor coil is controlled according to the location of a slot formed at a stator inside an electric motor so that a wasted wire can be reduced and a manufacturing cost and energy thus can be reduced, a cutting cover is installed at a cutting part to prevent a cut wire from popping up and protect the inside of the cutting part, and the length of a wire required for a process is set to enhance production efficiency.