Pivoting Winding Needle for Stator Coil Fastening
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Solution Overview
Problem
Existing devices for winding stators and fastening coil ends to terminals are limited in their ability to efficiently manage the winding process and secure coil ends automatically, particularly in designs with multiple coils and varying coil widths.
Innovation Solution
A device featuring a pivoting winding rod with a winding needle that can rotate between 90° and 100°, connected to a control rod driven by a programmable spindle, allowing for precise wire placement and automatic fixation of coil ends to terminals, along with a wire clamping and cutting device for simultaneous winding of multiple stators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a fixed winding needle is used for winding stators, then the winding process is simple, but the coil ends cannot be automatically fastened to terminals
Solution Approach 1:
The winding needle is made pivotable relative to the winding rod, allowing it to change orientation dynamically. The needle can be positioned at different angles (e.g., perpendicular to the rod for winding, parallel for fastening) to perform multiple functions automatically, eliminating the need for separate fastening devices and achieving automatic coil end fastening to terminals.
2Adaptability or versatility
If the winding needle is fixed in one position, then the device structure is simple, but it cannot handle varying coil configurations
Solution Approach 1:
The pivotable winding needle can be positioned at different angles relative to the winding rod according to different winding requirements. This dynamic positioning capability allows the same device to handle various coil configurations (different widths, pitches, and patterns) without requiring multiple specialized needles or complex adjustment mechanisms.
3Ease of operation
If manual fastening of coil ends is used, then the device structure is simple, but manual labor is required and precision is reduced
Solution Approach 1:
The winding and fastening functions are merged into a single automated process using the pivotable needle. The needle automatically performs both the winding operation and the fastening operation by simply changing its orientation, eliminating the need for separate manual fastening steps and reducing labor while maintaining precision.
Data Source
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AI summary
The device has a winding bar adjustable in two axial directions (x,z), where the two axial directions are perpendicular to each other. A winding needle (34) at the winding bar is arranged swiveling around a third axial direction (y) that is perpendicular to the two axial directions continuously by program control at any angle position within a given maximum swiveling area. An INDEENDENT CLAIM is also included for a method for automatic winding of coils in grooves of a stator of an electric machine and attaching coil ends at front side terminals.