Parallel Upper Die Bending Apparatus for Electric Motor Coils
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Solution Overview
Problem
Existing bending apparatuses for forming coil segments in electric rotary machines are oversized due to the need for upper dies to move obliquely upward, increasing the size of the apparatus and requiring separate equipment for bending end portions, which complicates the process and increases size further.
Innovation Solution
An electric conductor bending apparatus with an upper die that moves parallel to the conductor's surface and a lower die that moves in an up-and-down direction, allowing for parallel movement to reduce the working space and apparatus size, along with a control unit to manage the movement mechanisms, enabling efficient bending of multiple conductors simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the upper die moves obliquely upward to withdraw from the working space, then the working space is ensured, but the size of the bending apparatus increases
Solution Approach 1:
The upper die moves in a direction parallel to the upper surface of the electric conductor (horizontal dimension) instead of moving obliquely upward (diagonal/vertical dimension). This dimensional change allows the upper die to withdraw from the working space while minimizing the increase in apparatus size, as the movement is confined to a parallel plane rather than requiring additional vertical clearance.
2Ease of manufacture
If a separate bending apparatus is used to bend end portions, then the bending function is achieved, but the overall size and complexity increases
Solution Approach 1:
The upper die is designed to perform multiple functions: it bends the connecting portion into an S-shape and also bends both end portions into U-shapes. By combining these bending operations into a single die and process step, the patent eliminates the need for separate bending apparatus, thereby reducing overall apparatus size and simplifying the device configuration.
Solution Approach 2:
The upper die serves multiple purposes within a single operational cycle: it forms the S-shaped connecting portion and simultaneously forms the U-shaped end portions. This multi-functionality allows one component to replace what would traditionally require multiple separate tools or machines, reducing complexity while maintaining manufacturing capability.
3Volume of stationary object
If the upper die moves parallel to the conductor surface, then the apparatus size is reduced, but the movement mechanism becomes more constrained
Solution Approach 1:
The upper die is designed with dynamic movement capability along a guide rail or guide groove that constrains it to move parallel to the upper surface of the electric conductor. This dynamic constraint system provides the necessary movement freedom within the parallel plane while ensuring the die remains properly positioned and oriented throughout the bending operation, balancing size reduction with operational versatility.
Data Source
AI summary
A bending apparatus (10) includes an upper first die (11), an upper second die (12), a lower die (13), a control unit (20), an upper first moving mechanism (21), an upper second moving mechanism (22), a lower moving mechanism (23), a holding die (31), and a moving and rotating mechanism (32). The lower die (13) is moved in an upper direction after the upper first die (11) and the upper second die (12) are moved to the front, whereby four coil segments (4) are bent. When the upper second die (12) is moved to a first withdrawal position in the rear direction after the four coil segments (4) are bent, a working space for the holding die (31) is ensured.