Inner Tool for Electric Machine Laminated Core Winding
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Solution Overview
Problem
Existing methods for forming windings in electrical machine laminated cores are inefficient and harsh on conductor materials, as they require manual handling and separation of wire elements, which can lead to material damage and increased production time.
Innovation Solution
An inner tool and method for producing a semi-finished product for a laminated core, featuring a tool body with receptacles for laminated core segments and tool elements that guide conductor sections into receiving grooves, allowing for efficient and gentle introduction of windings between pole teeth, and a device for producing laminated cores that includes a feeding mechanism for meandering conductor arrangements and a yoke assembly for joining core segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling and separation of wire elements is used to form windings in laminated cores, then flexibility in handling conductor material is maintained, but production time increases and material damage occurs
Solution Approach 1:
The patent introduces an inner tool as an intermediary device between the conductor material and the laminated core. This inner tool includes guide elements that automatically guide conductor sections into receiving grooves, eliminating the need for manual wire separation and handling. The guide elements act as mediators that precisely position the conductor material without direct manual intervention, thereby reducing production time and preventing material damage that would occur during manual handling.
Solution Approach 2:
The inner tool is prepared in advance with pre-positioned guide elements and receptacles for laminated core segments. The conductor sections are fed through the inner tool which already has the receiving grooves prepared, allowing automatic alignment and insertion. This preliminary preparation of the tooling system enables continuous automated production without time-consuming manual wire separation and positioning operations.
2Ease of manufacture
If wire separation elements are arranged on a slide component to separate conductors, then wire separation is achieved, but the device complexity increases and manual operation is required
Solution Approach 1:
The inner tool is divided into multiple functional segments including separate guide elements for different conductor paths, individual receptacles for laminated core segments, and distinct tool elements for holding and guiding. This segmentation allows each component to perform its specific function independently without requiring complex moving mechanisms like slides. The guide elements are distributed throughout the tool body rather than concentrated on a single movable component, simplifying the overall structure while maintaining wire separation capability.
3Manufacturing precision
If laminated core segments are assembled manually and windings are introduced step-by-step, then precision in alignment is maintained, but production efficiency decreases
Solution Approach 1:
The patent replaces manual mechanical assembly operations with an automated inner tool system. The tool includes guide elements that mechanically guide conductor sections into precise alignment with receiving grooves, and receptacles that hold laminated core segments in predetermined positions. This mechanical guidance system ensures accurate alignment without requiring manual positioning, while the automated feed mechanism introduces windings continuously, significantly improving production efficiency compared to step-by-step manual assembly.
Data Source
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AI summary
The invention relates to an internal tool (1) for producing a semi-finished product for a laminated core of an electric machine, comprising: a tool body (2); receptacles (4) which are formed and arranged on the tool body (2) along a circumferential surface (3) at intervals from one another, each to receive a laminated core segment (5) of a laminated core, such that a laminated core segment (5) arranged on the receptacle projects radially from the tool body (2) and receiving grooves for conductor sections of a coil winding are formed between adjacent laminated core segments (5); and tool elements (6) which are assigned to the laminated core segments (5) and arranged to support the laminated core segments (5) on the tool body (2) and to guide the conductor sections of the coil winding into the receiving grooves in the region of the opposite end sections when inserted into the receiving grooves.Furthermore, a method for forming an internal tool (1) for the production of a semi-finished product for a lamination stack of an electric machine and a device for producing a lamination stack for an electric machine are provided.