Coil Wire Interlacing Without Post-Forming Deformation
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Solution Overview
Problem
Existing methods for manufacturing coil assemblies for electric rotating machines require a deforming process after interlacing, which increases man-hours and risks damage to insulating coats, particularly when using triangular wave-shaped coil wires.
Innovation Solution
A method involving sequential rotating steps to interlace coil wires with predetermined positioning and synchronized rotation, eliminating the need for post-interlacing deformation and reducing the risk of damaging insulating coats, while allowing for high-speed interlacing with smaller, less costly equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If triangular wave-shaped coil wires are used for interlacing, then the interlacing structure can be formed, but additional deforming process is required which increases man-hour and may damage insulating coats
Solution Approach 1:
The coil wires are pre-formed with bend portions at predetermined positions before the interlacing process. This preliminary shaping allows the wires to be directly interlaced without requiring subsequent deforming processes, thereby reducing man-hour and eliminating the risk of insulating coat damage during post-interlacing deformation.
Solution Approach 2:
Instead of forming the final triangular wave shape after interlacing (as in conventional methods), the invention inverts the sequence by pre-forming the bend portions before interlacing. This reversal of the process sequence eliminates the need for post-interlacing deformation steps.
2Ease of manufacture
If triangular wave-shaped coil wires are used for interlacing, then the interlacing structure can be formed, but the risk of damaging insulating coats increases during deforming process
Solution Approach 1:
The bend portions are pre-formed on the coil wires before interlacing, so that the wires are already in their final shape when interlacing occurs. This eliminates subsequent deforming operations that would otherwise risk damaging the insulating coats, thereby maintaining reliability.
Solution Approach 2:
The invention inverts the conventional sequence by forming the triangular wave shape before interlacing rather than after. This reversal eliminates the deforming step that causes insulating coat damage, thus preserving the integrity of the insulation.
3Productivity
If conventional interlacing methods are used, then coil wires can be interlaced, but the process requires complex deforming operations with multiple moving members
Solution Approach 1:
The coil wires are pre-shaped with bend portions at the required positions before interlacing. This eliminates the need for complex deforming equipment with multiple moving members during the interlacing process, simplifying the device while maintaining high productivity.
Solution Approach 2:
By inverting the process sequence to form the final shape before interlacing, the invention eliminates the need for post-interlacing deforming equipment, thereby reducing device complexity while preserving interlacing speed.
Data Source
AI summary
At one ends of a pair of coil wires 30, a pair of turn portions 42 are crossed. Further, the other ends of the coil wires 30 are held such that an angle θ between the axes of the coil wires 30 falls in a predetermined range (e.g., greater than or equal to 10° and less than or equal to 90°). Then, the coil wires 30 are rotated respectively about their axes in the same direction, so that corresponding pairs of turn portions 42 of the coil wires 30 are sequentially crossed from the one ends to the other ends, thereby interlacing the coil wires 30.