Dynamo Electric Machine Core Winding Wire Tension Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing technologies for winding coils of dynamo electric machines face issues with excessive wire tension, leading to wire stretching and waste during termination operations, and inefficiencies in positioning and cutting wire paths, resulting in suboptimal core quality and increased waste.
Innovation Solution
A system that includes a wire tension control mechanism using pulley wheels and motors to maintain consistent tension, combined with programmable motion systems for precise wire placement and reduced cutting operations, allowing for accurate positioning and minimized waste wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the wire dispenser is relatively moved with respect to the core to deposit the wire on a predetermined trajectory, then the termination wire positioning precision is improved, but the device complexity increases due to rotation mechanisms required to change dispenser orientation
Solution Approach 1:
The wire dispenser is made dynamically reconfigurable through a rotation mechanism that allows it to change orientation between perpendicular to the core axis during winding and parallel to the core axis during termination. This dynamic adaptation enables the same device to perform multiple functions with high precision without requiring separate fixed-position dispensers for each operation.
2Reliability
If the wire tension is increased during winding operations, then the wire control is improved, but the wire stretching and waste increase during termination operations
Solution Approach 1:
The wire tension is dynamically adjusted based on the operational phase. During winding operations, higher tension is applied to maintain wire control and prevent sagging. During termination operations, the tension is reduced to prevent excessive stretching and minimize waste. This dynamic tension control is achieved through a motorized wire feeding system that can vary the pulling force according to the current operation stage.
3Adaptability or versatility
If the dispenser structure extends along the core to accomplish intermediate termination paths, then the termination capability is improved, but the device complexity and wire path length increase
Solution Approach 1:
The dispenser structure is made extendable along the core axis through a telescopic or articulated mechanism. This allows the dispenser to reach intermediate termination points on the core that would otherwise be inaccessible. The extension capability is dynamically activated only when intermediate termination is required, maintaining versatility while minimizing structural complexity during standard winding operations.
Data Source
AI summary
An apparatus used in terminating and winding coils of a core of a dynamo electric machine. The coils being formed from at least an electric wire and the core having a longitudinal axis. The coils are wound by relatively moving a wire dispenser with respect to a core with relative motions of translation and rotation; at least a stretch of wire extends from the coil; and the stretch of wire is provided with a portion for a termination connection to a termination structure of the core, such as a tang. The method avoids waste cut wire in the apparatus. The core is provided with a groove at an end to receive at least a wire in the path of the wire for the termination of the coils. The apparatus comprises a wire deflector positioned adjacent the end of the core, where the groove is located, in order to intercept and align the wire with the groove. The apparatus can comprise a device for applying torques in two directions on a pulley wheel for feeding wire as a function of the position of the dispenser in the translation and the position of the core in the rotations.