Fan Stator Coil Lead Wire Holders for Automated Winding
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Solution Overview
Problem
Conventional fan stator coil winding operations are labor-intensive and time-consuming, with manual handling required for twisting and trimming lead wire ends, leading to inefficiencies and a low yield rate due to inconsistent strand thickness and length, and issues with tin welding and exposed wire sections causing short circuits.
Innovation Solution
The method involves using coil lead wire holders to manage and connect lead wire ends, reducing the need for manual twisting and trimming, and employing automated processes for winding and electrical connection, including welding and soldering techniques to enhance efficiency and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual twisting and trimming of lead wire ends is performed, then the lead wire ends can be organized, but labor consumption and manufacturing time increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-organizing and positioning the lead wire ends (front ends 541 and back ends 542) into twisted strands before the winding process. This preliminary organization eliminates the need for manual twisting and trimming after winding, as the lead wires are already prepared in the correct configuration. The twisted strands are formed with consistent thickness and length in advance, enabling automated winding without subsequent manual intervention.
2Ease of operation
If twisted strands are formed manually by different operators, then the lead wire ends can be organized, but inconsistency in strand thickness and length occurs
Solution Approach 1:
The patent applies self-service by designing a self-aligning mechanism where the lead wire ends automatically position themselves into consistent twisted strands. The winding machine incorporates guides and positioning fixtures that ensure uniform strand formation without relying on operator skill. The system self-regulates the twisting process to maintain consistent thickness and length across all strands, eliminating variability introduced by different operators.
3Manufacturing precision
If manual trimming is performed to adjust strand length, then the lead wire ends can be organized, but manufacturing time and labor increase
Solution Approach 1:
The patent applies preliminary action by pre-cutting and pre-positioning the lead wire ends to the exact required length before the winding process. The winding machine is equipped with automated cutting devices that trim the lead wires to precise lengths during the setup phase. This eliminates the need for subsequent manual trimming operations, as all strands are already configured with the correct length for direct automated winding and welding.
4Ease of operation
If expanded vias are used to accommodate thicker twisted strands, then the strands can be connected to the circuit board, but tin leaking and large weld nuggets occur
Solution Approach 1:
The patent applies the extraction principle by removing the twisting operation that creates thick strands. Instead of forming twisted strands from multiple lead wire ends, the system uses individual lead wires or minimally processed strands that maintain their original thickness. This extraction of the problematic twisting step allows the use of standard via sizes in the circuit board, avoiding tin leaking and large weld nuggets while maintaining reliable electrical connections.
5Reliability
If remained sections of front and back ends are left after welding, then the electrical connection is complete, but short circuits may occur and manual cutting is required
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-cutting the lead wire lengths to exact specifications that account for the welding process. The system is designed so that after welding, no excess material remains that could cause short circuits. This preliminary precision cutting eliminates the need for post-welding manual cutting operations, maintaining both reliability and productivity.
6Productivity
If automated winding machine is used, then the coil winding can be done efficiently, but twisting and trimming steps still require manual handling
Solution Approach 1:
The patent applies merging by integrating the twisting, trimming, and winding operations into a single automated machine system. The winding machine incorporates built-in mechanisms for twisting lead wires into consistent strands and trimming them to precise lengths, all performed automatically during the winding process. This merging of previously separate manual operations into one automated system eliminates manual handling while maintaining ease of operation through centralized control.
Data Source
AI summary
A manufacturing method of fan stator structure includes the steps of providing a fan stator; providing a plurality of coil lead wire holders at an end of the fan stator; and winding lead wires on the fan stator to form coils, and setting and connecting a front end and a back end of each of the lead wires to the coil lead wire holders. The above method eliminates the drawbacks of the conventional fan stator coil winding operation, such as requiring manual twisting and trimming of the lead wire front ends and back ends and leaking of tin solder occurred during welding of the lead wires to a circuit board.