Compressed Strand Adhesive Application for Traction Motors
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Solution Overview
Problem
Existing methods for producing compressed strands fail to provide an optimal solution for selectively applying adhesive, particularly bonding varnish, in the head region where electrical connections are made, leading to undesirable adhesive application and subsequent removal challenges.
Innovation Solution
A method where adhesive is applied to wire intermediate sections before twisting and compacting, allowing for selective application and avoiding adhesive in the head region, using shaping devices to introduce adhesive into the wire packet, ensuring defined and uniform distribution between wires, and utilizing various forms of adhesives like bonding varnish for mechanical fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied to the entire wire packet including head regions, then uniform distribution and mechanical strength are improved, but adhesive removal complexity and time increase
Solution Approach 1:
The patent applies adhesive only to specific regions (intermediate sections) of the wire packet rather than uniformly across the entire packet including head regions. This localized application is achieved through shaping devices that define application zones, providing mechanical strength where needed while avoiding adhesive in head regions that would complicate removal and interfere with electrical connections.
2Manufacturing precision
If adhesive is applied before twisting, then adhesive distribution uniformity is improved, but adhesive application precision requirements increase
Solution Approach 1:
The patent performs adhesive application before the twisting process, allowing the adhesive to be distributed uniformly throughout the wire packet intermediate sections. The shaping devices prepare the wire packet in advance by defining the geometry and creating cavities that guide adhesive flow, ensuring uniform distribution without requiring excessively precise application during the main production flow.
3Stability of the object's composition
If bonding varnish is used to mechanically connect wires, then vibration resistance is improved, but electrical connection reliability in head regions deteriorates
Solution Approach 1:
The patent applies bonding varnish only to intermediate sections of the wire packet where mechanical connection is needed, deliberately excluding head regions. This creates different functional zones: intermediate sections with adhesive for vibration resistance, and head regions without adhesive for reliable electrical connections and clean welding surfaces.
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
This method enables fast, defined, and uniform adhesive application, increasing mechanical strength, reducing vibrations and noise, and ensuring reliable electrical contact with clean and consistent compressed strand heads, thereby enhancing the efficiency of the compressed strand production process.
Implementation Method 1
adhesive, in particular bonding varnish, is to be understood as adhesive resin that has the task of mechanically connecting the individual wires of a stranded wire or a winding to one another
Implementation Method 2
the at least one half-loop, ring, or coil together with the shaping device define an interior space with an open cross section, in particular an insertion cross section, for the adhesive to be introduced
Implementation Method 3
compacting the wire packet
Data Source
AI summary
The present invention relates to a method for producing a compressed strand (F) from a wire, comprising at least the method steps of: a) shaping said wire (1) into at least one half-loop, ring, or coil in a shaping device (2); b) acting upon said at least one ring, half-loop or coil with adhesive (7); c) twisting said at least one half-loop, ring, or coil into a wire packet (1′) in a twisting device (4); d) compacting said wire packet (D) in a compacting device (5), as well as to a method for producing an electric motor, in particular a traction motor for a motor vehicle, comprising a stator (S), where the stator is equipped with at least one compressed strand (F), where the compressed strand (F) is produced according to the method of at least one of the preceding claims, as well as to the use of a compressed strand (F) in an electric motor, in particular in a traction motor for a motor vehicle, characterized in that it is a compressed strand (F) according to at least one of the preceding claims.