Plugged Wave Winding Assembly Automation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing plugged wave windings lack automation and precision, leading to potential damage from plastic deformation and permanent deformation, which can result in unstable downstream processes and increased risk of insulation damage.
Innovation Solution
An apparatus and method featuring movable guide elements and a bending device that allows for elastic bending of wave winding parts, ensuring precise alignment and plugging without plastic deformation, utilizing a relative displacement device for automated and process-safe assembly of wave winding parts into a plugged wave winding mat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual methods are used for manufacturing plugged wave windings, then flexibility is maintained, but automation and precision are lacking leading to potential damage from plastic deformation
Solution Approach 1:
The patent replaces manual mechanical operations with an automated apparatus that uses guide elements and a bending device. The system automatically positions wave winding parts using guide elements (48a, 48b, 50a, 50b) and performs controlled bending, eliminating manual handling while maintaining precision through the structured guidance system and controlled deformation process.
2Ease of manufacture
If plastic deformation is used during plugging, then assembly is achieved, but permanent deformation and insulation damage occur
Solution Approach 1:
The patent changes the deformation parameter from plastic to elastic by controlling the bending process. The bending device (44) applies controlled force to deflect portions (32) of wave winding parts elastically, allowing the material to return to its original shape after plugging, thereby avoiding permanent deformation and insulation damage while still achieving proper assembly.
3Device complexity
If fixed guide elements are used, then structure is simple, but precision and adaptability are limited
Solution Approach 1:
The patent employs movable guide elements (48a, 48b, 50a, 50b) that can move between a guide position and a release position. This dynamic capability allows the guide elements to provide precise alignment during the plugging operation and then move out of the way to allow winding heads to pass through, achieving both precision and operational flexibility without significantly increasing structural complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables automated, process-safe production of plugged wave winding mats with reduced risk of insulation damage and permanent deformation, ensuring stable downstream processes and improved manufacturing efficiency.
Implementation Method 1
a bending device for bending portions (32) of at least one of the wave winding parts (14, 16) such that one or more of the winding heads (30) directed to the other wave winding part (16, 14) are displaced in a second transverse direction (Q2)
Data Source
AI summary
A device and method for producing a plugged wave winding by plugging together first and second wave winding parts. A first receptacle receiving the first wave winding part includes elements for guiding first wave winding part straight wire sections. A second receptacle receives the second wave winding part and has elements for guiding second wave winding part straight wire sections. A device for bending portions of at least one of the wave winding parts is configured to displace one or more of the winding heads directed towards the other wave winding part to plug the wave winding parts together. A relative displacement device pushes and plugs the first and second wave winding parts into one another. The first and/or second guide elements are movable between a position for guiding the straight wire sections and a position for releasing the path of winding heads while plugging into one another.