Hairpin Winding Forming with Adaptive Control
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Solution Overview
Problem
The production of winding elements, particularly hairpin elements for electromotor stators, faces challenges in achieving consistent product quality and minimizing waste, as existing methods require calibration and testing for each conductor piece, leading to inefficiencies and inconsistencies in forming processes.
Innovation Solution
A method and device that use a forming device to convert conductor pieces into desired forms through kinematic position changes, with real-time detection of actual forms and adjustments to forming influences to match target forms, allowing for precise and adaptive forming of complex geometries with minimal waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional calibration and testing procedures are used for each conductor piece, then product quality consistency can be monitored, but production efficiency decreases and waste increases
Solution Approach 1:
The patent applies preliminary action by pre-defining target forms and forming influences in a database before actual production. The system stores predetermined forming parameters (bending moments, torsional moments, forming sequences) that can be directly applied during production, eliminating the need for calibration and testing of each conductor piece while maintaining product quality consistency
Solution Approach 2:
The patent uses copying by creating digital representations (target forms) of the desired conductor geometry and storing them in a database. These digital models serve as templates that guide the forming process, allowing repeated production of identical high-precision forms without manual calibration or inspection
2Ease of manufacture
If conventional forming methods are used with fixed parameters, then production process is simple, but manufacturing precision and adaptability to various forms decrease
Solution Approach 1:
The patent applies dynamics by making the forming parameters adaptive rather than fixed. The system dynamically selects forming influences from the database based on the specific conductor piece characteristics and desired target form, allowing the forming process to adapt to various geometries while maintaining simplicity through automated parameter selection
Solution Approach 2:
The patent uses parameter changes by storing multiple sets of forming parameters (bending moments, torsional moments, forming sequences) in the database corresponding to different target forms. The system changes these parameters automatically based on the required geometry, enabling high manufacturing precision across various conductor forms without complicating the actual forming process
3Device complexity
If conventional forming methods are used, then device complexity is low, but waste generation and energy consumption increase
Solution Approach 1:
The patent applies feedback by implementing a closed-loop system where the actual forming results are measured and compared against the target form stored in the database. The system uses this feedback information to automatically adjust forming parameters for subsequent conductor pieces, minimizing material waste by achieving precise forms from the first attempt without requiring recalibration or producing defective pieces
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
This approach enables the efficient and precise formation of winding elements with reduced waste and improved product consistency by continuously adjusting forming influences based on actual and target forms, ensuring accurate and consistent production of complex geometries.
Implementation Method 1
These forming influences are typically bending moment and torque moment. In other words, during the forming method, the conductor piece is bent and additionally or alternatively twisted
Implementation Method 2
These forming influences are typically bending moment and torque moment. In other words, during the forming method, the conductor piece is bent and additionally or alternatively twisted
Implementation Method 3
The detection device determines the three-dimensional course of the formed conductor piece, its three-dimensional form, its actual form resulting from the forming
Data Source
AI summary
The invention relates to a method and device (10) for forming winding elements, in particular hairpin winding elements, from a conductor piece (12).