Plug-in Coil Element Arrangement on Workpiece Carrier
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Solution Overview
Problem
Existing methods for producing coil elements for electric machines lack efficiency and flexibility in mass production, particularly in configuring winding patterns, number of conductors, grooves, and layers, leading to inefficiencies in assembly and increased installation space requirements.
Innovation Solution
A method and device utilizing a workpiece carrier with a displacement device and gripping device to efficiently arrange and hold rod-shaped coil elements, allowing for flexible configuration and transfer of coil elements into desired positions on the carrier, enabling the formation of single or multi-layer arrangements with closed contours, and facilitating further processing such as insertion into coil cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional methods are used to produce coil element arrangements, then assembly steps are simplified, but production efficiency and flexibility are reduced
Solution Approach 1:
The coil elements are pre-positioned on a workpiece carrier in their final arrangement pattern before being transferred to the coil core. This preliminary positioning on the carrier allows for efficient mass production while maintaining flexibility in configuration, as the elements are already arranged in the desired pattern (single-layer, multi-layer, closed contours, basket-like structures) before the actual assembly into the coil core begins
Solution Approach 2:
The production process is segmented into distinct functional stages: (1) positioning coil elements on the workpiece carrier using a displacement device, (2) transferring the arranged elements to the coil core using a gripping device, and (3) inserting the pre-assembled arrangement into the coil core. This segmentation allows each device to specialize in its function, improving overall production efficiency while keeping the system manageable
2Adaptability or versatility
If fixed configuration methods are used for coil elements, then manufacturing is simpler, but flexibility in winding patterns and conductor arrangements is reduced
Solution Approach 1:
The displacement device is designed to dynamically position coil elements at different locations on the workpiece carrier, allowing the system to adapt to various winding patterns, conductor arrangements, groove configurations, and layer structures. The device can adjust its positioning to create single-layer or multi-layer arrangements, closed contours, and basket-like structures as needed, providing manufacturing flexibility without sacrificing ease of operation
Solution Approach 2:
The workpiece carrier serves multiple functions: it acts as a positioning platform for the displacement device, a temporary holding structure for arranged coil elements, and a transfer interface for the gripping device. This multi-functionality allows a single device to handle various coil element configurations and arrangements, enhancing adaptability while maintaining manufacturing simplicity
Data Source
AI summary
A method is presented for producing an arrangement of coil elements for a plug-in coil of an electric machine. The method includes providing a workpiece carrier and producing an arrangement of rod-shaped coil elements for a plug-in coil of an electric machine on the workpiece carrier, wherein the following is respectively provided for the rod-shaped coil elements: accommodating and holding the coil elements by means of a displacement device; supplying the coil element onto the workpiece carrier by means of the displacement device into an assigned proximal position on the workpiece carrier, wherein the coil elements are hereby displaced form a distal position into the assigned proximal position with respect to the workpiece carrier; and transferring the coil elements in the proximal position on the workpiece carrier from the displacement device by a gripping device, which is formed on the workpiece carrier.