Helical Flat-Conductor Coil Joining for Mass Production
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Solution Overview
Problem
Current coil manufacturing techniques lack efficiency in mass-producing high-quality coils with enhanced space factor and heat dissipation performance, and are prone to property deterioration due to cutting and welding processes.
Innovation Solution
A coil manufacturing apparatus and method that involves a bending device to incline flat conductors and a welding device for pressure welding, forming a helical structure with improved space factor and heat dissipation, while removing unwanted portions to prevent property deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional coil manufacturing techniques are used, then coils can be produced, but productivity is insufficient for mass-production and property deterioration occurs due to cutting and welding processes
Solution Approach 1:
The flat conductor is divided into multiple segments that are joined through pressure welding to form the helical coil structure. This segmentation allows continuous production without traditional cutting and welding operations, enabling mass-production while avoiding property deterioration
Solution Approach 2:
The invention replaces conventional cutting and welding processes with pressure welding technology. This mechanical substitution eliminates the harmful effects of traditional welding on material properties while maintaining joint strength and enabling high-speed mass-production
2Manufacturing precision
If flat conductors are welded through conventional methods, then coils can be formed, but space factor in the core is not enhanced and heat dissipation performance is limited
Solution Approach 1:
The flat conductors are formed into a helical (curved) structure through pressure welding, which optimizes the space utilization within the motor core. This curved configuration enhances the space factor while improving heat dissipation pathways through the coil structure
Solution Approach 2:
The invention changes the geometric parameters of the conductor configuration by forming flat conductors into helical structures with optimized dimensions. This parameter optimization simultaneously enhances space factor and heat dissipation performance
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 mass-production of high-quality coils with enhanced space factor and heat dissipation performance, minimizing property deterioration caused by cutting and welding, and improving productivity.
Implementation Method 1
pressing end faces of the one flat conductor and the another flat conductor against each other along a strip longitudinal direction and joining the flat conductors through pressure welding
Implementation Method 2
bending each of the flat conductors such that one portion, of each of the plurality of flat conductors, extending along a helical traveling direction is inclined with respect to the other portion
Data Source
AI summary
The coil manufacturing apparatus includes: a bending device configured to bend each of a plurality of flat conductors; and a welding device configured to weld the plurality of flat conductors. The bending device is a unit configured to bend each of the flat conductors before being supplied to the welding device. The welding device includes a first holding portion and a second holding portion disposed facing each other, and a driving portion configured to move the first holding portion and the second holding portion. The helical structure body is formed by pressing end faces of the one flat conductor and the another flat conductor against each other along a strip longitudinal direction and joining the flat conductors through pressure welding while reducing a distance in the strip longitudinal direction. The coil manufacturing apparatus includes a removing device configured to remove an unwanted portion of the flat conductors generated by welding.