Electric Motor Coil Winding with Dynamic Turn Path Control
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Solution Overview
Problem
Existing coil winding methods, such as the flyer winding technique, result in statistical scatter and varying wire length, leading to inconsistent operating parameters and increased material usage, heat losses, and inefficiencies in electric motors.
Innovation Solution
A method where a flyer arm dynamically controls the wire movement around a stator or rotor tooth using an image acquisition device and computer unit to optimize the turn course, minimizing wire length and ensuring reproducible operating parameters by calculating the shortest path and adjusting in real-time based on previous winding scenarios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If flyer winding technique is used with fixed sequence control, then production speed is high and production cost is low, but wire length varies by up to 8% and operating parameters are inconsistent
Solution Approach 1:
The patent applies dynamics by transitioning from fixed sequence control to dynamic control of the flyer arm. The control unit continuously adjusts the flyer arm's movement based on real-time position data from the evaluation unit, enabling adaptive wire laying that maintains consistency despite high-speed variations. This dynamic adjustment resolves the contradiction by allowing fast production while ensuring precise wire length control.
Solution Approach 2:
The patent implements feedback through the evaluation unit that continuously monitors the position and course of already applied turns, and feeds this information back to the control unit. This feedback loop enables real-time optimization of the flyer arm's movement, ensuring that each new turn follows an optimized course that minimizes wire length while maintaining production speed. The feedback mechanism directly addresses the wire length consistency issue.
2Productivity
If wire is laid with fixed sequence at high winding speed, then production is fast and cost-effective, but statistical scatter occurs and wire length varies
Solution Approach 1:
The patent applies preliminary action by evaluating the position and course of already applied turns before laying the next turn. The control unit uses this preliminary information to determine the optimized course for the current turn, ensuring minimal wire length from the outset. This preliminary evaluation and planning prevents excessive wire consumption while maintaining high winding speed.
Solution Approach 2:
The dynamic control of the flyer arm allows the system to adapt to actual winding conditions in real-time. By continuously adjusting the flyer arm's movement based on feedback from the evaluation unit, the system minimizes wire length for each turn while maintaining high production speed, thereby reducing overall wire consumption.
3Reliability
If wire length is increased to ensure sufficient coverage, then winding coverage is improved, but ohmic resistance increases and heat losses occur
Solution Approach 1:
The patent replaces the mechanical fixed-sequence flyer arm movement with a controlled system that uses evaluation and calculation units to determine optimized paths. This substitution of mechanical randomness with intelligent control enables precise wire placement that achieves sufficient coverage with minimal wire length, thereby reducing ohmic resistance and heat losses.
Solution Approach 2:
The patent changes the control parameters from fixed sequence to dynamically optimized parameters. The control unit adjusts the flyer arm's movement parameters based on real-time evaluation of the winding pattern, ensuring that the wire follows the most efficient path. This parameter optimization achieves complete coverage while minimizing wire length and associated energy losses.
4Ease of manufacture
If flyer arm follows fixed pattern, then manufacturing process is simple, but wire cannot take shortest path and material is wasted
Solution Approach 1:
The patent applies self-service by enabling the winding system to automatically evaluate and optimize its own wire laying pattern. The evaluation unit monitors the winding process and the control unit automatically adjusts the flyer arm's path to minimize wire length. This self-optimizing capability eliminates material waste while maintaining manufacturing simplicity through automated control.
Solution Approach 2:
The patent replaces the simple but inefficient mechanical fixed-pattern flyer arm with an intelligent control system that uses evaluation and calculation units. This substitution maintains ease of manufacture through automated control while enabling the wire to follow the shortest possible path, thereby eliminating material waste.
Data Source
AI summary
A method for producing a winding of a coil around a component, of an electric motor, wherein in order to produce the winding, at least one wire is guided over at least one arm encircling the component in a rotational movement in such a way that the wire is wound around the component in successive turns, wherein at least one image acquisition device and/or at least one computer unit provides information about the course of turns that have already been wound, wherein the arm is dynamically controlled in a type of movement different from the encircling rotational movement, in such a way that the turn currently being applied by the movement follows a determined turn course that is optimized with respect to previously applied adjacent turns.