Flat Wire Stator Insertion Line With Continuous Loading and Winding
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Solution Overview
Problem
Existing automatic wire inserting devices for flat wire stators have low efficiency due to the inability to automatically load, transfer, and wind flat wires, resulting in inefficient wire insertion processes.
Innovation Solution
An automatic wire inserting device is designed with a winding displacement tooling, material loading and transfer mechanisms, wire coiling mechanisms, and a wire inserting mechanism, which enables the loading, arrangement, and winding of flat wires in a stator slot, improving the efficiency of wire insertion through mechanical arms and motor-driven components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If an existing automatic wire inserting device is used, then wire inserting can be automated, but wire inserting efficiency is relatively low because the device cannot automatically load, transfer, and wind the flat wire
Solution Approach 1:
The patent combines multiple previously separate operations (loading, transferring, winding, and inserting) into a single integrated device. The material loading mechanism loads flat wires, the material transfer mechanism transfers them to the winding displacement tooling, the wire coiling mechanism winds them into windings, and the wire inserting mechanism inserts them into the stator - all within one automated system that works continuously
Solution Approach 2:
The patent implements continuous operation through the wire body that circularly moves the winding displacement tooling between the material transfer mechanism and the wire coiling mechanism. While one set of mechanisms is winding, another is loading or transferring, eliminating idle time and maintaining continuous productive action throughout the system
2Productivity
If manual loading and transfer of flat wires is performed, then device complexity is reduced, but wire inserting efficiency decreases
Solution Approach 1:
The patent divides the complex loading and transfer process into distinct functional modules: the material loading mechanism with vibration-generating parts, the material transfer mechanism with clamping assemblies, and the winding displacement tooling. Each module handles a specific task, making the overall complex system manageable and efficient
Solution Approach 2:
The patent introduces intermediary components such as the material holder that temporarily holds flat wires during transfer, and the clamping assemblies that securely grip the wires during manipulation. These intermediaries facilitate smooth transitions between different mechanisms without requiring direct complex interaction between all components
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device enhances wire inserting efficiency by allowing for automatic loading, arrangement, and winding of flat wires, improving the overall process by enabling precise alignment and insertion into stator slots, thus increasing production efficiency.
Implementation Method 1
The material loading part is provided with a first vibration motor
Implementation Method 2
The material transfer part is provided with a second vibration motor
Implementation Method 3
a side that is of the baffle plate and that is opposite to the winding displacement plate is provided with a second cylinder, the second cylinder is capable of driving the baffle plate to move toward the winding displacement plate, to align the flat wires
Implementation Method 4
two mechanical arms, configured to: move the two wire coiling mechanisms alternately to the wire inserting mechanism, insert a winding on the wire coiling mechanism into the wire inserting mechanism, and the mechanical arm restores the wire coiling mechanism to a side of the wire body after the winding is separated
Data Source
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AI summary
The present invention relates to an automatic wire inserting device for producing a flat wire stator, which includes: a winding displacement tooling, configured for winding displacement of flat wires; a material loading mechanism, configured to load the flat wires one by one; a material transfer mechanism, configured to: clamp the flat wires loaded by the material loading mechanism one by one, and arrange the flat wires on the winding displacement tooling one by one; two wire coiling mechanisms, configured to wind the flat wires on the winding displacement tooling into windings; a wire body, configured to: drive the winding displacement tooling to circularly move between a wire coiling mechanism and the material transfer mechanism, to convey the winding displacement tooling on which the flat wires are arranged to the wire coiling mechanism, and move 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, configured to: shape a winding that is detached from the wire coiling mechanism and eject the shaped winding to be inserted into a stator. The present invention is characterized with an advantage of improved wire inserting efficiency.