Deformable Wire Guide for Electric Machine Coil Winding
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Solution Overview
Problem
Existing methods for maximizing wire fill in electric machine coils, such as those used in motors, face challenges in maintaining uniform and closely packed windings, leading to reduced slot fill and inferior coil formation due to issues like wire migration and separation during high-speed automated assembly.
Innovation Solution
The use of a wire guide with a deformable material that conforms to the wire as it is wound, featuring a tapered relieved portion and protrusions to maintain wire tension and alignment, ensuring precise placement and maximizing slot fill.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed automated assembly is used to wind wire around teeth, then productivity is improved, but wire uniformity and packing precision deteriorate due to wire migration and separation
Solution Approach 1:
A needle guide is introduced as an intermediary component between the wire and the teeth during the winding process. The needle guide maintains proper wire alignment and prevents wire migration and separation, enabling high-speed automated assembly to achieve both productivity improvement and manufacturing precision
Solution Approach 2:
The needle guide is designed with specific geometric parameters including a tapered relieved portion and protrusions that can be adjusted to optimize wire containment. By modifying these parameters, the system maintains wire packing uniformity while accommodating high-speed winding operations
2Quantity of substance
If wire is wound tightly in multiple layers to maximize slot fill, then wire density is improved, but maintaining wire alignment and preventing migration becomes more difficult
Solution Approach 1:
The needle guide features localized protrusions and a tapered relieved portion that create specific containment zones at critical locations where wire migration is most likely to occur. This local quality enhancement provides targeted support to maintain wire alignment stability while allowing tight multi-layer winding for maximum slot fill
3Strength
If rigid core structures with teeth are used for winding, then structural strength is improved, but wire access and positioning precision deteriorate
Solution Approach 1:
The needle guide serves as a mediator between the rigid core structure with teeth and the wire being wound. It compensates for the limitations of the rigid structure by providing precise wire positioning and alignment, enabling accurate wire placement while maintaining the structural strength of the rigid core
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 approach enhances the uniformity and density of wire packing within the coils, improving motor performance and reducing labor costs while maintaining assembly speed and accuracy.
Implementation Method 1
The use of a wire guide with a deformable material that conforms to the wire as it is wound
Data Source
AI summary
A wire assembly for use in an electric machine is provided. The assembly includes a member and a wire. The wire conducts electrical current. At least a portion of the wire is adapted to be wrapped at least partially around the member. The member defines a periphery of the member. At least a portion of the periphery of the member is conformable when the wire is wrapped at least partially around the member.