Coil Wire Braiding Method Preventing Deformation in Electric Rotary Machines
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Solution Overview
Problem
Existing methods for producing coil assemblies in electric rotary machines, such as motor-generators, often result in undesirable deformation of braided coil wires due to physical interference, making it difficult to achieve the desired geometry.
Innovation Solution
A method involving the offset arrangement and sequential turning of coil wires to minimize the angle between them, allowing for braiding or twisting without deformation, using a series of steps including arrangement, engagement, turning, crossing, and moving to ensure parallel alignment and minimize interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coil wires are braided by turning them around each other to avoid physical interference, then the braiding process can be completed, but the straight portions of the coil wires undergo undesirable deformation
Solution Approach 1:
The patent introduces a new dimensional approach by arranging coil wires in parallel along the axial direction rather than turning them around each other in the radial direction. The braiding is achieved by moving wires alternately in the axial direction and performing partial turning at engagement points, effectively changing the primary dimension of the braiding operation from radial rotation to axial progression with localized turning.
Solution Approach 2:
The patent segments the coil wires into distinct portions: straight portions that remain undeformed and are disposed in stator slots, and turned portions that are selectively turned at engagement points during braiding. This segmentation allows the straight portions to maintain their geometry while the turned portions accommodate the braiding process.
2Object-affected harmful factors
If the angle between first and second coil wires is kept great to avoid physical interference during rotation, then interference is avoided, but the straight portions of the coil wires are deformed
Solution Approach 1:
The patent applies local quality by allowing turning and angular changes only at specific engagement points where turned portions are located, while the straight portions maintain their parallel alignment and original geometry. This localized turning approach confines the angular changes to specific regions rather than affecting the entire coil wire structure.
Solution Approach 2:
Instead of maintaining a great angle between coil wires in the radial direction to avoid interference, the patent resolves interference by offsetting turned portions in the axial direction and performing braiding through sequential engagement and partial turning operations, effectively moving the interference avoidance strategy from angular separation to spatial offsetting in a different dimension.
3Ease of manufacture
If coil wires are turned around each other during braiding, then the braided coil assembly can be formed, but it becomes difficult to shape the coil wires into the desired geometry
Solution Approach 1:
The patent performs preliminary arrangement of coil wires in parallel alignment before the braiding process begins. The straight portions are pre-positioned to extend substantially parallel to each other, and the turned portions are pre-offset in the axial direction. This preliminary arrangement establishes the desired geometry early in the process, allowing subsequent braiding operations to proceed without compromising the final shape.
Solution Approach 2:
The patent segments the coil wire structure into straight portions that maintain the desired geometry and turned portions that accommodate braiding operations. By separating these functions into distinct portions, the straight portions can be shaped to the desired geometry independently while the turned portions are manipulated during braiding to achieve the required interlacing pattern.
Data Source
AI summary
A method of producing a coil assembly to be wound in a stator core with a plurality of slots. The method prepares a first and a second coil wire each of which is made up of in-slot portions and turned portions, arranges the first and second coil wires in parallel with the turned portions being offset from each other in a lengthwise direction thereof, moves the first coil wire to establish engagement of the turned portions of the first and second coil wires, turns the first coil wire about a pivot where the turned portions engage, crosses the first coil wire over the second coil wire around the pivot, and turns the first coil wire around the pivot so as to twist the turned portions of the first and second coil wires together. This sequence of steps is repeated to twist or braid the first and second coil wires without undesirable deformation thereof.