Fixed Arbor Wire Winding for Brushless Stator Automation
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Solution Overview
Problem
The high cost and complexity of existing automated wire winding machines for stators in electric motors, which require elaborate mechanical drives and multiple components, hinder efficient and cost-effective manufacturing.
Innovation Solution
A simplified method and mechanism using a fixed arbor with an elliptical port to support the stator and guide the wire, allowing for back-and-forth and radial motion along the arbor's major axis, enabling efficient winding of multiple wires simultaneously without additional wire feeding or guiding mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If elaborate mechanical drives and multiple components are used for automated wire winding, then automation capability is improved, but device complexity increases
Solution Approach 1:
The patent extracts and eliminates the complex mechanical drives, gears, and multiple wire feeding mechanisms from traditional winding machines. Instead, it uses a simple fixed arbor with an elliptical port that passively guides the wire through geometric constraint alone, achieving automation without elaborate mechanical components.
Solution Approach 2:
The elliptical port on the fixed arbor serves multiple functions simultaneously: it guides the wire, maintains proper wire position, and enables the winding motion through its geometry alone. The system serves itself by using the port's shape to automatically control wire placement without additional guiding mechanisms.
2Productivity
If multiple wires are wound simultaneously, then productivity is improved, but device complexity increases
Solution Approach 1:
The fixed arbor with elliptical port is designed to handle multiple wires simultaneously through a single guiding structure. The elliptical geometry naturally accommodates and guides multiple wire strands through the same port, enabling parallel winding of multiple stators without requiring separate feeding mechanisms for each wire.
Solution Approach 2:
The patent merges multiple wire feeding and guiding functions into a single fixed arbor structure. Instead of having separate mechanisms for each wire, all wires are fed through and guided by the same elliptical port, combining multiple functions into one simple component.
3Manufacturing precision
If traditional wire guiding mechanisms are used, then wire positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The elliptical port's geometry itself provides the wire positioning function. The shape of the port creates natural constraints that guide the wire along the desired path and maintain proper positioning throughout the winding process, eliminating the need for separate positioning mechanisms.
Solution Approach 2:
The elliptical (curved) geometry of the port provides smooth wire guidance and natural positioning. The curved path of the ellipse guides the wire through the winding motion while maintaining consistent positioning, replacing straight-line mechanical guides with a geometrically defined curved path.
Data Source
AI summary
A method and mechanism for automatic or manual winding of a stator. A fixed arbor serves to support the stator during the winding process, as well as a wire feed point and wire guide. A mechanism moves the stator in a back and forth motion along the major axis of the arbor. Proper axial position of the wire is maintained by the outer surface of the arbor and the axial slot itself. The arbor has a channel that serves to guide the wire, allowing it exit in each of the two possible longitudinal directions along the major axis of the arbor.