Flat Wire Stator Copper Forming with Modular 2D and 3D Shaping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current automatic copper wire forming devices for flat wire motor stators are limited in producing multiple shapes of copper wires, leading to low production efficiency and the need for multiple devices.
Innovation Solution
A device comprising a loading mechanism, enamel removal mechanism, chamfering mechanism, wire feeding mechanism, cut-off mechanism, 2D forming mechanism, transit mechanism, 3D forming mechanism, and unloading mechanism, which enables the production of multiple copper wire shapes by automatically processing and forming copper wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate forming devices are used for different copper wire shapes, then each device can produce its specific shape with high precision, but the overall production efficiency decreases and the device complexity increases
Solution Approach 1:
The forming device is designed with interchangeable forming modules that can be quickly swapped to produce different copper wire shapes (U-shape, open slot, closed slot). This universal design allows a single device to perform multiple functions, eliminating the need for separate dedicated devices for each wire shape while maintaining manufacturing precision through module-specific forming capabilities.
Solution Approach 2:
The device incorporates adjustable and interchangeable forming modules that can be dynamically configured based on production requirements. The forming modules can be quickly replaced or adjusted to change the wire shape being produced, enabling the system to adapt to different production needs without sacrificing precision or requiring multiple fixed devices.
2Manufacturing precision
If multiple separate forming devices are used for different copper wire shapes, then each device can be optimized for its specific function, but the device complexity and space requirements increase
Solution Approach 1:
The patent merges multiple specialized forming devices into a single integrated system by combining interchangeable forming modules with a common base structure, control system, and wire feeding mechanism. This consolidation reduces the total number of devices from multiple separate units to one multi-functional device, simplifying the overall system while preserving the precision of individual forming operations.
Solution Approach 2:
By designing the forming device with universal interchangeable modules, the system can be optimized for each specific wire shape through module selection rather than requiring separate dedicated devices. Each module maintains the precision needed for its specific function while the overall system complexity is reduced through standardization and modularity.
3Productivity
If manual wire feeding and processing is used, then the device complexity is reduced, but the productivity and manufacturing precision decrease
Solution Approach 1:
The device incorporates automatic wire feeding mechanisms that self-regulate the wire supply to the forming modules, eliminating the need for manual wire handling. The system automatically feeds wire through the forming process, maintains proper tension, and ensures consistent material delivery, thereby improving productivity and precision while the automated systems manage themselves with minimal human intervention.
Solution Approach 2:
The automated wire feeding system incorporates feedback mechanisms that monitor wire consumption, tension, and positioning in real-time. This feedback enables the control system to adjust feeding rates and positions dynamically, ensuring consistent wire delivery to the forming modules and maintaining manufacturing precision throughout the automated process.
4Productivity
If a single forming device produces multiple copper wire shapes, then the productivity increases and device complexity decreases, but the manufacturing precision for each shape may be compromised
Solution Approach 1:
The forming device is segmented into independent interchangeable modules, each specialized for producing a specific copper wire shape (U-shape, open slot, closed slot). This segmentation allows each module to maintain its own optimized forming geometry and parameters for high precision, while the modular architecture enables rapid switching between shapes to achieve high productivity. Each segment preserves the precision of dedicated equipment while the system as a whole achieves multi-shape capability.
Data Source
AI summary
A device for forming copper wires of a flat wire motor stator includes a loading mechanism, automatically discharging copper wire rolls and straighten copper wires; an enamel removal mechanism, automatically removing enamel on four side surfaces of the straightened copper wire; a chamfering mechanism, cutting away four edges of the enamel-removed copper wire at a same position; a wire feeding mechanism, automatically feeding the wires during processing of the loading mechanism, the enamel removal mechanism and the chamfering mechanism; a cut-off mechanism, cutting off the processed copper wire at a fixed length; a 2D forming mechanism, carrying out 2D forming on the copper wire that has been cut off at the fixed length; a transit mechanism, transferring the 2D-formed copper wire onto a 3D forming mechanism; the 3D forming mechanism, carrying out 3D punch forming on the 2D-formed copper wire; and an unloading part, collecting the 3D-formed copper wire.