Multi-Wire Wave Winding Bending Without Wire Stretching
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Solution Overview
Problem
Current methods for producing wave windings for electrical machines often result in material stress and unintended stretching or elongation of wire conductors during the bending process, which can lead to inefficient and potentially damaged coil windings.
Innovation Solution
A method and device that simultaneously bend multiple wire conductors on a mold core tool, allowing for relative movement between them to prevent material stress, using a feed device to feed the conductors in a way that they are bent together, either lying one on top of the other or next to each other, thereby reducing or avoiding expansions or stretching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If wire conductors are bent multiple times to form wave windings, then the coil winding structure is created, but material stress and unintended stretching or elongation occur
Solution Approach 1:
The patent applies the dynamics principle by allowing the wire conductors to move relative to each other in the longitudinal direction during the bending process. The feeding device enables this dynamic adjustment, permitting the wires to shift position as they are bent around the forming core tool. This dynamic capability prevents material stress and stretching by allowing the wires to naturally adjust their positions during forming, thereby maintaining wire conductor integrity while achieving the required wave winding shape.
2Productivity
If multiple wire conductors are bent simultaneously on a forming core tool, then production efficiency is improved, but material stress increases without relative movement capability
Solution Approach 1:
The feeding device incorporates dynamic adjustment capability that allows wire conductors to move relative to each other in the longitudinal direction during simultaneous bending. This dynamic feature enables multiple wires to be bent at the same time on the forming core tool while preventing material stress accumulation, as each wire can independently adjust its position during the bending process.
3Ease of manufacture
If wire conductors are fed rigidly without relative movement, then feeding control is simplified, but stretching and elongation occur during bending
Solution Approach 1:
The feeding device implements dynamic adjustment that permits wire conductors to move relative to each other in the longitudinal direction during feeding and bending. This dynamic capability maintains manufacturing precision by preventing stretching and elongation, while the overall feeding process remains controlled and manageable through the device's design.
Data Source
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AI summary
The invention relates to a method and a device for producing a multi-wire bend of a wave winding for a coil winding of an electrical machine.The method comprises the following: providing several wire conductors (4), each made of flat wire material; feeding the several wire conductors (4) to a winding device (2) by means of a feeding device (1); producing a multi-wire bend of a wave winding for a coil winding of an electrical machine by means of the winding device (2), wherein the several wire conductors (4) are bent several times simultaneously on a forming core tool (3) of the winding device (2) to form the multi-wire bend of the wave winding, and for this purpose a relative movement between the several wire conductors (4) in the longitudinal direction of the several wire conductors (4) is supplied to the winding device (2) by means of the feeding device (1), at least during bending; and removing the multi-wire bend from the forming core tool (3).