Hairpin Conductor Forming Machine with Dynamic Clamp Control
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Solution Overview
Problem
Existing machines for producing bent wire components face challenges in achieving precise geometry with low tolerances and flexibility, leading to increased downtimes and costs due to complex setup requirements and variations in wire element dimensions for stator units.
Innovation Solution
A machine with a feed device, a bending die, and movable clamps controlled by a unit to manipulate the angle and spacing of wire ends, allowing for precise bending and adaptation of geometry, along with a system for easily exchanging die halves to accommodate different wire geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a bending die is used to bend wire elements, then the wire components achieve the desired geometry, but corrections to geometry require changing die geometry which increases setup complexity and downtime
Solution Approach 1:
The patent replaces the static bending die with dynamic clamps that can be adjusted during operation. The clamps are movable along the wire element and can be positioned at different locations to achieve different bending geometries without changing the physical die structure. This dynamic adjustment capability resolves the contradiction by maintaining manufacturing precision while reducing setup complexity.
Solution Approach 2:
The patent changes the parameters of the clamping force and clamp position rather than changing the die geometry. By adjusting the position and force parameters of the clamps, different wire component geometries can be achieved with the same physical apparatus, eliminating the need for complex die changes and reducing setup complexity.
2Manufacturing precision
If a bending die is used to bend wire elements, then the wire components achieve the desired geometry, but corrections to geometry require changing die geometry which increases downtime
Solution Approach 1:
The movable clamps allow for quick repositioning and reconfiguration without the time-consuming process of changing entire die assemblies. The clamps can be adjusted during operation to produce different geometries, significantly reducing downtime while maintaining manufacturing precision.
3Adaptability or versatility
If clamps are made movable in translation and rotation, then flexibility in wire geometry is improved, but device complexity increases
Solution Approach 1:
The patent divides the clamping system into multiple independent clamps that can move individually. Each clamp can be adjusted in translation and rotation independently, providing flexibility in wire geometry while keeping each individual clamp mechanism relatively simple. This segmentation allows complex overall functionality to be achieved through simpler individual 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
Enables precise and flexible production of bent wire components with reduced downtime and increased efficiency by allowing for coordinated movement of clamps and easy die configuration, ensuring optimal field formation in stator units.
Implementation Method 1
a pair of clamps arranged on either side of the bending die, adapted to grip the wire elements
Implementation Method 2
bending die which is designed and set up to bend the intermediate section of the wire elements at least in sections out of the plane of its two legs
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to a machine (10) for producing bent wire components, comprising a feeding device for feeding flat pre-bent wire elements (D) with two legs extending in a plane and an intermediate section provided between the legs, a bending die (12) which is designed and configured to bend the intermediate section of the wire elements (D) at least partially out of the plane of their two legs, a pair of clamps (14a, 14b) arranged on both sides of the bending die (12) which are configured to grip the wire elements (D) and are furthermore movable in a coordinated translational and/or rotational manner; and a control unit which is operationally coupled to the bending die (12) and the pair of clamps (14a, 14b) and is configured to control the bending die (12) and the pair of clamps (14a, 14b) for coordinated bending and movement.Furthermore, the invention relates to a method for operating such a machine (10).