Rotating Dispenser Arm Wire Guide for Dynamo Core Winding
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Solution Overview
Problem
Existing methods for winding coils in electric dynamo machines with slots having external openings face challenges in achieving optimal wire tension, correct positioning, and maximum filling of slots, often resulting in wire loss and suboptimal use of space due to issues with wire guide trajectories and needle thickness.
Innovation Solution
A system comprising a rotating dispenser arm with a tubular member and wire guides that rotate and translate to ensure precise wire delivery and positioning, minimizing wire bending and tension loss, while allowing for efficient layer formation and connection to termination structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a needle is made sufficiently narrow to pass through slot openings for radial stratification, then turn positioning precision is improved, but the needle thickness occupies empty slot space and impedes maximum filling of turns
Solution Approach 1:
The patent extracts the wire delivery function from a traditional needle and implements it through a wire guide assembly that operates externally to the slot openings. The wire guide assembly includes a guide member positioned outside the slot that directs wire into the slot without the needle itself occupying slot space, thereby eliminating the space occupation problem while maintaining precise wire delivery for radial stratification.
Solution Approach 2:
The patent introduces a wire guide assembly as an intermediary between the wire source and the slot. This intermediary component (comprising guide members, support members, and positioning mechanisms) enables precise wire delivery and radial stratification without requiring a physical needle to penetrate the slot, thus avoiding the space occupation issue while achieving both precision and maximum slot filling.
2Productivity
If a rotating flyer arm with wire guide is used for winding, then productivity is improved, but wire tension is lost due to excessive wire release from the needle
Solution Approach 1:
The patent implements a dynamic wire guide assembly that moves in coordination with the rotating flyer arm. The wire guide assembly includes movable support members and adjustable guide members that adapt their position during rotation, maintaining optimal wire tension throughout the winding process. This dynamic adjustment prevents excessive wire release and tension loss while preserving high-speed productivity.
Solution Approach 2:
The patent incorporates feedback mechanisms through tension sensing and positioning systems that monitor wire tension during the winding process. The wire guide assembly adjusts its position and wire delivery rate based on real-time tension feedback, ensuring consistent wire tension is maintained even at high rotational speeds, thereby preventing tension loss while maintaining productivity.
3Manufacturing precision
If wire guides are progressively distanced from the axial end of the core during layer formation, then radial stratification is achieved, but device complexity increases
Solution Approach 1:
The patent designs a universal wire guide assembly that performs multiple functions: it guides wire for radial stratification, positions wire for angular layer formation, and maintains tension control throughout the process. The wire guide assembly includes multi-functional components such as adjustable guide members that can position wire at different radial distances and angular positions, eliminating the need for separate mechanisms for each function and thereby reducing overall device complexity.
Solution Approach 2:
The patent segments the wire guide assembly into modular components (guide members, support members, positioning mechanisms) that can independently adjust to achieve radial stratification and angular layer formation. This segmentation allows each component to perform a specific function while working together as an integrated system, simplifying the overall mechanism compared to a monolithic complex wire guide system.
Data Source
AI summary
Apparatus and method for winding coils (B) of conductor wire (W) around respective poles (10c) of a core (10) of a component of a electric dynamo machine, wherein a dispenser arm (11) rotates around the poles to deliver the wire (W) to form wire turns; a first wire guide (32) is positioned and moved during winding adjacent to an axial end (A) of a pole (10c) being wound; a second wire guide (36) is positioned and moved in a first slot (10a) adjacent to the pole (10c) being wound; a third wire guide (37) is positioned and moved in a second slot (10b) adjacent to the pole (10c) being wound. A termination member (80) is capable of achieving connection of the coil leads to termination structures (91) of the core.