Modular Bending Device for Wire Ends in Stator Coils
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Solution Overview
Problem
Existing bending devices for wire ends in electrical machine stators are complex and difficult to manufacture and maintain, particularly in forming coil windings for high-power electrical machines like those used in electric vehicles, where precise and controlled bending is necessary for efficient coil formation.
Innovation Solution
A bending device with a modular design featuring multiple receiving and rotating units connected via releasable connections, allowing for easy assembly and disassembly, and a controller for precise rotation control, enabling efficient bending of wire ends in both radial and circumferential directions to form coil pairs for welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a bending device with multiple receiving and rotating units is used to enable precise bending of wire ends in radial and circumferential directions, then manufacturing precision and coil formation quality are improved, but device complexity increases making it difficult to manufacture and maintain
Solution Approach 1:
The bending device is divided into multiple independent receiving and rotating units (first, second, third, fourth units), each capable of receiving and bending wire ends in specific directions. Each unit can be independently controlled and maintained, reducing the complexity of the entire system while achieving precise multi-directional bending of wire ends to form high-quality coil windings
2Ease of repair
If receiving and rotating units are made detachable for easier maintenance, then ease of repair is improved, but reliability of the bending device may deteriorate due to connection points
Solution Approach 1:
The receiving and rotating units are designed as detachable modules that can be easily separated from the main device structure. This segmentation allows individual units to be removed for maintenance or replacement without affecting the entire device, improving ease of repair while maintaining reliability through modular design that isolates potential failure points
3Productivity
If multiple wire ends are processed simultaneously in the same circumferential station, then productivity is improved, but manufacturing precision may deteriorate due to interference between wire ends
Solution Approach 1:
The device processes multiple wire ends simultaneously by dividing them into different radial groups (first, second, third, fourth wire ends at different radial distances). Each receiving and rotating unit handles wire ends at its specific radial position independently, enabling parallel processing of multiple wire ends without mutual interference, thus maintaining high precision while improving productivity
Data Source
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AI summary
In order to increase the ease of maintenance, the invention relates to a bending device (54) for bending wire ends (34, 34a-34d) protruding out of an annular housing (18), comprising a first receiving and rotating device (160a) having a first receiving and rotating unit (162a) and a first drive element (166a), wherein the first receiving and rotating unit (162a) is connected to the first drive element (166a) via a first detachable connection (188a); and a second receiving and rotating device (160b) having a second receiving and rotating unit (162b) and a second rotatably driven drive element (166b) extending in the circumferential direction, wherein the second receiving and rotating unit (162b) is connected to the second drive element (166b) via a second detachable connection (188b); the receiving and rotating units (162a, 162b) can be rotated relative to one another about a common axis of rotation, and, in a relative assembly and disassembly position of the first and second receiving and rotating devices (160a, 160b), connection elements (196b) of the second receiving and rotating device (160b) are accessible via through-openings (198a) in the first receiving and rotating device (160a) for assembly and disassembly purposes. The invention also relates to a corresponding assembly and disassembly method.