Dual-Axis Winding Carrier Coupling for Faster Electric Machine Coils
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Solution Overview
Problem
The existing winding devices for electrical machines, particularly those with toothed chains or externally grooved stators/rotors, require costly and complex servo-motor switching mechanisms, leading to high investment and maintenance efforts, as well as lengthy process times due to the need for multiple winding positions and complex servo-motor operations.
Innovation Solution
A winding device with a coupling device that transmits a rotating drive movement to a winding tool, allowing it to rotate around two axes of rotation, eliminating the need for a servo-motor switching mechanism by using a single drive device for both spindle and drum axis rotations, thus simplifying the winding process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a servo-motor switching mechanism is used to rotate the support unit around two axes, then the winding device can achieve precise positioning and rotation control, but the investment costs and maintenance efforts increase significantly
Solution Approach 1:
The patent combines the functions of two separate servo-motors into a single drive device. The coupling device transmits the rotation of one drive device to both the first axis (spindle axis) and the second axis (drum axis), eliminating the need for multiple independent drive mechanisms while maintaining precise positioning capability.
Solution Approach 2:
The single drive device is designed to perform multiple functions by controlling the support unit's rotation around both the first axis and the second axis through the coupling device. This multi-functional approach replaces the need for specialized servo-motors for each axis, reducing complexity while preserving precision.
2Measurement precision
If a servo-motor switching mechanism is used for rotating the support unit, then precise control is achieved, but the maintenance effort increases
Solution Approach 1:
By merging the drive functions into a single drive device, the number of components requiring maintenance is reduced. Instead of maintaining two separate servo-motors and their switching mechanisms, only one drive device and its associated coupling mechanism need to be maintained, significantly reducing maintenance effort.
3Manufacturing precision
If multiple winding positions and complex servo-motor operations are used, then precise winding is achieved, but the process time increases
Solution Approach 1:
The coupling device enables continuous rotation of the support unit around both axes without interruption or switching delays. The single drive device can continuously transmit rotational motion through the coupling mechanism, eliminating the stop-start operations and switching times associated with multi-servo-motor systems, thus maintaining precision while increasing winding speed.
Data Source
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Figure 7
AI summary
A winding device (1) for producing an arrangement with several winding carriers (111, 112, 113) and a winding made of wire material (2) arranged thereon comprises a winding tool (3). Each winding carrier (111, 112, 113) carries a partial winding (121, 122, 123). The winding tool (3) comprises a base (31) rotatable about a first axis of rotation (S), a receiving device (35) with a support unit (101) holding the winding carriers (111, 112, 113), and a boom (33) radially offset from the first axis of rotation (S), which is connected to the base (31) and on which the receiving device (35) is rotatably mounted about a second axis of rotation (T). The second axis of rotation (T) is oriented transversely to the first axis of rotation (S). A drive device (5) associated with the winding tool (3) is set up to provide rotary drive motion.A coupling device (7) serves to transmit the rotary drive movement of the drive device (5) to the winding tool (3), either the receiving device (35) rotates around the first axis of rotation (S) or the second axis of rotation (T).