Flat Wire Stator Winding Assembly for Faster Wire Insertion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current manufacturing processes for hairpin permanent magnet synchronous motors are inefficient due to the slow insertion of copper wires into stator windings, lacking a mature mass production line for flat wire stators, which hampers production efficiency.
Innovation Solution
An automatic wire inserting process for flat wire stators involves arranging copper wires on winding displacement toolings, conveying them to a wire coiling mechanism, coiling into a preset structure, and transferring it into the stator, utilizing multiple winding layers and slots to increase efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If copper wires are inserted one by one into wire slots by a wire inserting device, then the insertion process is simple to implement, but the wire inserting speed is slow and production efficiency is low
Solution Approach 1:
The patent applies preliminary action by pre-arranging multiple copper wires on the winding displacement tooling in the correct sequence and positions before the winding process. This preparation allows the wires to be automatically fed and coiled at high speed during the winding operation, eliminating the need for slow individual insertion during production.
Solution Approach 2:
The winding displacement tooling serves as an intermediary device that holds and positions multiple copper wires in advance. It mediates between the wire storage and the winding mechanism, enabling the wire coiling mechanism to process multiple wires simultaneously through automatic feeding and coiling, thereby increasing production efficiency.
2Productivity
If copper wires are winded as a whole after insertion, then the winding process is simplified, but the insertion speed becomes the bottleneck affecting overall production efficiency
Solution Approach 1:
The patent prepares multiple copper wires in advance on the winding displacement tooling with correct positioning and spacing. This preliminary arrangement allows the wire coiling mechanism to automatically feed and coil wires at high speed without being constrained by slow individual insertion processes, thus resolving the bottleneck.
Solution Approach 2:
The patent segments the wire processing into distinct phases: pre-arrangement on tooling, automatic feeding, coiling, and insertion. By segmenting the process, the time-consuming insertion step is separated from the high-speed coiling operation, allowing each phase to be optimized independently and improving overall production efficiency.
3Productivity
If multiple copper wires are arranged and coiled simultaneously to form preset winding structure, then wire inserting speed increases significantly, but the arrangement and coiling process becomes more complex
Solution Approach 1:
The winding displacement tooling is designed as a multi-functional device that combines wire holding, positioning, and sequential feeding capabilities. This universal tooling handles multiple copper wires of different specifications through standardized arrangements, reducing the need for separate specialized devices for each wire type and managing complexity through design integration.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to an automatic wire inserting process for a flat wire stator, which includes the following steps: S1: arranging copper wires in sequence on multiple winding displacement toolings according to a quantity of layers and a quantity of slots of different stator winding structures; S2: conveying the multiple winding displacement toolings on which the copper wires are arranged to a wire coiling mechanism; S3: the wire coiling mechanism coils the copper wires arranged on the winding displacement tooling to a winding assembly in sequence, to form a preset winding structure; and S4: transferring and inserting the preset winding structure into the stator. The present invention is characterized with an advantage of an increased wire inserting speed.