Layer Coil Forming with Offset Flat-Wire Winding Sections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of high-quality single- or multi-layer coils with flat wires, particularly those with rectangular cross sections, is challenging due to their large size and difficulty in automated manufacturing, which hinders their application in advanced electrical drives like electric vehicles.
Innovation Solution
A method involving the deformation of flat wires to create offset winding sections, followed by precise winding within designated planes using a two-part deforming tool, allowing for sequential layer formation and automation, with optional S-shaped deforming regions and guiding elements for efficient coil layer production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flat wire with rectangular cross section is used to form layer coils, then electrical properties are improved, but manufacturing difficulty increases
Solution Approach 1:
The manufacturing process is segmented into two distinct steps: first deforming the flat wire to create winding sections with offsets, then winding these pre-formed sections into coil layers. This segmentation allows each step to be optimized independently, making automated production feasible while maintaining the rectangular cross-section geometry that provides good electrical properties.
Solution Approach 2:
The winding sections are pre-formed with offsets before the actual winding process. By creating the deformed geometry in advance through a separate deforming step, the subsequent winding operation becomes simpler and more suitable for automation, while the final coil structure retains the desired rectangular cross-section for optimal electrical performance.
2Manufacturing precision
If deforming force is applied to create winding sections, then coil structure precision is improved, but force expenditure increases
Solution Approach 1:
The process separates high-force deforming operations from low-force winding operations. The deforming tool applies sufficient force to create precise offsets in the flat wire, while the subsequent winding step requires minimal force since the geometry is already established. This segmentation allows precision to be achieved without continuously applying high force throughout the entire manufacturing process.
Solution Approach 2:
The offset geometry is preliminarily created in the winding sections before winding begins. This preliminary deformation concentrates the force expenditure in a controlled initial step, after which the pre-formed sections can be wound with minimal additional force, reducing overall force expenditure while maintaining structural precision.
3Productivity
If automated production is implemented, then productivity is improved, but process complexity increases
Solution Approach 1:
The manufacturing process is divided into two independent modules: a deforming module that creates winding sections with offsets, and a winding module that forms coil layers. Each module can be independently automated and controlled, simplifying the overall automation architecture compared to attempting to automate a single complex continuous process. This modular segmentation enables staged implementation and easier maintenance of automated systems.
Solution Approach 2:
By pre-forming the winding sections with required offsets before the winding operation, the automation system only needs to handle relatively simple tasks in each stage rather than coordinating complex simultaneous operations. The deforming step prepares the material in advance, making the subsequent winding operation straightforward and easier to automate with standard equipment.
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 quick and reliable production of high-quality layer coils with reduced force expenditure, improved automatability, and adaptability for integration into stator slots, enhancing electrical properties and manufacturing efficiency.
Implementation Method 1
deforming the flat wire along a deforming direction to create one or more winding sections designed as offset in relation to a starting section of the flat wire
Data Source
AI summary
A method for producing a single- or multi-layer coil, includes the steps of: providing a flat wire; deforming the flat wire along a deforming direction in order to produce one or more winding sections which are designed to be offset relative to a starting section of the flat wire, wherein the one or more winding sections are designed to form coil layers which run on winding planes arranged in an offset manner relative to the deforming direction; and winding the one or more winding sections on the respective winding plane in order to form one or more coil layers.