Hairpin Conductor Circular Forming with Segmented Holding Units
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Solution Overview
Problem
Existing apparatuses for producing final configurations of conductor elements, such as hairpins, are complex and inflexible, limiting the ability to change configurations or add special pins, making it difficult to achieve a circular configuration suitable for stator cores in electrodynamic machines.
Innovation Solution
An apparatus with multiple holding segment devices that hold and move conductor elements in a controlled manner to form a circular configuration, allowing for flexible final configurations by varying movement paths and replacing holding segment units, enabling the creation of conductor elements with different diameters and types, such as hairpins and special pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing apparatuses are used to produce final configurations of conductor elements, then the production process can be carried out, but the apparatus complexity increases and flexibility to change configurations is limited
Solution Approach 1:
The apparatus is divided into multiple holding segment devices, each capable of independently holding and moving conductor elements. This segmentation allows different segments to be configured differently, enabling flexible final configurations without requiring complex modifications to the entire apparatus. Each holding segment device can be replaced or reconfigured independently to produce different conductor element arrangements.
Solution Approach 2:
The holding segment devices are designed with universal functionality to handle various types of conductor elements (hairpins, special pins) and create different final configurations. The same basic device structure can be used for multiple purposes by changing the movement paths and arrangement of holding segment units, eliminating the need for extensive modifications when changing production requirements.
2Adaptability or versatility
If existing apparatuses are used to produce final configurations of conductor elements, then the production process can be carried out, but the ability to add special pins is limited
Solution Approach 1:
The apparatus uses separate holding segment devices that can independently handle different types of conductor elements. This allows special pins to be added in specific segments without affecting other parts of the apparatus, enabling flexible addition of special pins without increasing overall apparatus complexity.
Solution Approach 2:
The holding segment devices have movable holding segment units that can be dynamically positioned and reconfigured. This dynamic capability allows the apparatus to adapt to different production requirements, including the addition of special pins, by simply changing the movement paths and positions of the holding segment units rather than modifying the apparatus structure.
3Shape
If holding segment units move conductor elements from starting position to final position, then the circular configuration is formed, but the movement path complexity increases
Solution Approach 1:
The holding segment units move along curved paths to form the circular final configuration of conductor elements. By designing the movement paths with appropriate curvature, the apparatus directly produces the desired circular shape without requiring complex intermediate steps or additional deformation operations, simplifying the overall movement path while achieving the target geometry.
Solution Approach 2:
The holding segment devices hold and pre-position the conductor elements in the correct orientation and arrangement before the final movement to the circular configuration. This preliminary action ensures that the conductor elements are properly aligned and prepared, reducing the complexity of the movement path needed to achieve the final circular configuration.
Data Source
AI summary
The invention relates to an apparatus (10) for producing an in particular circular final configuration (12) of conductor elements (14), preferably hairpins, which are designed in particular with a rectangular conductor cross-section, for fitting a stator core, wherein each conductor element (14) has at least one, in particular two, limbs (16). The invention also relates to a corresponding machine (58) and to a corresponding method.