Movable Wire Guides for Compact Stator Winding
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Solution Overview
Problem
In dynamoelectric machine winding processes, the large size of winding needles relative to core slots prevents them from moving within the slots, necessitating wire deflection and guidance to achieve accurate positioning and high wire occupancy in compact stator designs, where space constraints limit the movement of wire guides and needles.
Innovation Solution
The use of movable wire guides supported adjacent to the core, which are positioned and moved in conjunction with the needle to guide the wire into slots, allowing for relative motion between the needle and wire guides to achieve accurate wire placement and stratification along the radial direction of the core, enabling efficient winding of wire coils without the needle entering the slots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the needle size is increased to handle large quantity of wire, then wire occupancy increases, but the needle cannot move within the slots due to large dimensions
Solution Approach 1:
The needle is extracted from the slot during winding operations. Instead of moving the needle within the slot as in conventional winding, the needle remains outside the slot and delivers wire to the slot opening. The wire is then guided into the slot by a wire guide, separating the needle positioning function from the wire insertion function.
Solution Approach 2:
A wire guide is introduced as an intermediary component between the needle and the slot. The wire guide receives wire from the needle and guides it into the slot, enabling the needle to remain outside the slot while still achieving wire insertion. This mediator resolves the conflict between needle size and slot accessibility.
2Manufacturing precision
If wire guides are added to guide wire into slots, then wire positioning accuracy improves, but device complexity increases due to support means required within stator interior
Solution Approach 1:
The wire guide is designed to perform multiple functions: it guides wire from the needle into the slot, provides structural support, and defines the insertion path. By combining multiple functions into a single component, the need for separate support means is reduced, lowering overall device complexity while maintaining positioning accuracy.
3Volume of moving object
If stator dimensions are reduced to optimize compactness, then space efficiency improves, but space for needle movement and wire guide support is reduced
Solution Approach 1:
The needle is extracted from the slot during winding operations. Instead of moving the needle within the slot as in conventional winding, the needle remains outside the slot and delivers wire to the slot opening. The wire is then guided into the slot by a wire guide, separating the needle positioning function from the wire insertion function.
Solution Approach 2:
The winding process transitions from a primarily radial needle movement within the slot to a combination of axial needle positioning outside the slot and radial wire guide insertion. This dimensional change allows the needle to operate in a different spatial plane, reducing the radial space requirements within the slot while maintaining winding capability.
Data Source
AI summary
An apparatus and a method for winding wire coils in cores of dynamo electric machine using needles that are relatively movable with respect to the cores. Wire guides are provided that are also relatively movable with respect to the needle and the core so that the wire leaving the needle can be delivered to predetermined positions around the poles of the core to wind the wire coils. The wire guides are supported adjacent to the ends of the core by support means which have portions occupying positions of the needle trajectory during winding. The portion of the support means are movable as a function of the position occupied by the needle around the poles so that the needle can move without being obstructed. The arrangement enhances accuracy of guiding and positioning of the wire to form the wire coils and is suitable for compactly sized cores.