Flat Wire Stator Insertion Line With Alternating Coiling Modules
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Solution Overview
Problem
Conventional automatic wire inserting devices for flat wire stators have low efficiency due to the manual loading, transfer, and winding of flat wires, which hampers the production process.
Innovation Solution
An automatic wire inserting device is designed with a winding displacement tooling, material loading and transfer mechanisms, wire coiling mechanisms, and mechanical arms to automate the loading, arrangement, and winding of flat wires, enabling efficient and precise insertion into the stator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual loading, transfer, and winding of flat wires are used, then device complexity is reduced, but productivity is low
Solution Approach 1:
The device is divided into multiple independent functional modules: material loading mechanism, material transfer mechanism, wire coiling mechanism, and wire inserting mechanism. Each module performs a specific task in the wire inserting process, allowing for automated operation while maintaining manageable system complexity through modular design.
Solution Approach 2:
The wire body serves multiple functions: it conveys the winding displacement tooling to the wire coiling mechanism, transports completed windings back to the material transfer mechanism, and coordinates the alternating operation of two wire coiling mechanisms. This multi-functional component reduces the need for separate dedicated mechanisms for each operation.
2Productivity
If automated material loading and transfer mechanisms are added, then productivity is improved, but device complexity increases
Solution Approach 1:
The material loading mechanism pre-loads flat wires onto the winding displacement tooling before the wire coiling operation begins. The material transfer mechanism pre-positions and clamps the flat wires in advance. These preliminary actions ensure that when the wire coiling mechanism operates, all materials are ready, enabling continuous automated production without manual intervention.
Solution Approach 2:
The material transfer mechanism acts as an intermediary between the material loading mechanism and the wire coiling mechanism. It receives pre-loaded flat wires, clamps them securely, and positions them for the wire coiling mechanism. This intermediary component facilitates smooth material flow between different stages of the automated process.
3Productivity
If multiple wire coiling mechanisms are used, then productivity is improved, but device complexity increases
Solution Approach 1:
Two wire coiling mechanisms operate alternately in a periodic cycle. While one wire coiling mechanism is winding flat wires into windings, the other is being restored to its initial position by the mechanical arm. This periodic alternating operation ensures continuous production without idle time, effectively doubling the wire coiling capacity while using a coordinated system rather than two independent complex systems.
Solution Approach 2:
The mechanical arm dynamically repositions the wire coiling mechanisms between operations. After one wire coiling mechanism completes its winding task, the mechanical arm moves it to the wire inserting mechanism, then restores it to the side of the wire body where it can rewind flat wires. This dynamic repositioning enables the alternating operation pattern and maintains system flexibility.
Data Source
AI summary
An automatic wire inserting device for producing a flat wire stator includes a winding displacement tooling, winding displacement of flat wires; a material loading mechanism, loading each flat wire; a material transfer mechanism, clamping each flat wire loaded by the material loading mechanism, and arranging each flat wire on the winding displacement tooling; two wire coiling mechanisms, winding the flat wires into windings; a wire body, driving the winding displacement tooling to circularly move between a wire coiling mechanism and the material transfer mechanism, conveying the winding displacement tooling to the wire coiling mechanism, and moving the winding displacement tooling on which winding of the flat wires are completed by using the wire coiling mechanism to the material transfer mechanism; and a wire inserting mechanism, shaping a winding that is detached from the wire coiling mechanism and ejecting the shaped winding to be inserted into a stator.