Plug-In Coil Grip Layout for Precise Core Groove Insertion
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Solution Overview
Problem
Existing methods for producing plug-in coil arrangements for electric machines are inefficient and material-intensive, lacking a reliable means to pre-position and securely insert rod-shaped or hairpin-shaped coil elements into core grooves.
Innovation Solution
A method and apparatus involving a grip apparatus with dual grip devices to pre-position, hold, and insert coil elements into core grooves, allowing for efficient, material-saving, and geometrically defined arrangement, with optional clamping and non-clamping mechanisms to maintain pre-alignment during insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a grip apparatus with dual grip devices is used to pre-position and hold coil elements, then manufacturing precision and geometric arrangement are improved, but device complexity increases
Solution Approach 1:
The grip apparatus is divided into two independent grip devices operating in different grip planes. The first grip device operates in a first grip plane to initially position the coil elements, while the second grip device operates in a second grip plane (arranged beneath and spaced apart from the first) to secure and guide the legs during insertion. This segmentation allows each device to specialize in specific positioning tasks, achieving high geometric precision without requiring a single overly complex mechanism.
Solution Approach 2:
The invention introduces a spatial dimension by arranging the two grip devices in different planes (first grip plane and second grip plane spaced apart vertically). This dimensional separation allows the apparatus to control coil element positioning from multiple levels, ensuring precise geometric arrangement while keeping each individual grip device relatively simple in structure.
2Productivity
If pre-positioning and secure holding of coil elements is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The first grip device performs preliminary positioning of the coil elements in the first grip plane before the insertion process begins. This pre-positioning action ensures that the coil elements are correctly aligned and spaced beforehand, enabling the insertion process to proceed efficiently without interruptions for real-time adjustment, thus improving productivity.
Solution Approach 2:
The dual grip devices work continuously throughout the insertion process. The first grip device maintains holding force on the coil elements while the second grip device simultaneously guides the legs into the grooves. This continuous action from multiple grip planes ensures uninterrupted production flow and high productivity.
3Manufacturing precision
If dual grip devices operating in different planes are used, then manufacturing precision is improved, but ease of operation decreases
Solution Approach 1:
The two grip devices operating in different planes are controlled through a unified control system that coordinates their actions. The control unit synchronizes the first and second grip devices, managing their respective movements and forces as an integrated system. This merging of control simplifies the operator's task by providing centralized control over the complex dual-plane operation, maintaining ease of operation while achieving high precision.
Data Source
AI summary
A method is presented for producing an arrangement for a plug-in coil of an electric machine, having the following steps: providing an arrangement of coil elements, which each are embodied as a rod-shaped coil element and are pre-aligned with one another; gripping the arrangement of coil elements by way of a grip apparatus, wherein the grip apparatus grips the arrangement of coil element by way of a first grip device in a first grip plane and by way of a second grip device in a second grip plane which is arranged beneath the first grip plane and at a distance therefrom; holding the arrangement of coil elements by way of the grip apparatus and inserting legs of the coil element into allocated grooves of a core; and releasing the grip apparatus from the arrangement of coil elements.