Radial Chuck Wire Holding for Accurate Coil End Positioning

Solution Overview

Problem

Existing methods for automating the positioning of wire ends after winding around stator or rotor cores are complex, costly, and prone to errors due to randomly bent wire ends, which complicates the automation of motor manufacturing processes.

Innovation Solution

A workpiece holding apparatus with chucks that move radially to grip and tension the wire before cutting, allowing for orderly positioning without additional members for handling bent wire ends, using a simple configuration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If wire ends are positioned after cutting using traditional methods, then wire ends can be handled, but the apparatus size, complexity, and cost increase significantly

Engineering Contradiction:

Improvewire end positioning capabilityVSAvoidapparatus configuration

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The wire end is gripped by the chuck mechanism in its tensioned state before cutting occurs. This preliminary gripping action eliminates the need for complex post-cutting positioning mechanisms, as the wire end is already secured in the correct position before the cutting process begins.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The chuck mechanism that normally serves to hold the workpiece during winding is made to perform the additional function of gripping and positioning the wire end. This multi-functional use of existing components eliminates the need for separate wire end positioning mechanisms, thereby reducing apparatus complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If wire ends are positioned after cutting using traditional methods, then wire ends can be handled, but the manufacturing cost increases

Engineering Contradiction:

Improvewire end positioning capabilityVSAvoidapparatus cost

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The chuck mechanism that normally serves to hold the workpiece during winding is made to perform the additional function of gripping and positioning the wire end. This multi-functional use of existing components eliminates the need for separate wire end positioning mechanisms, thereby reducing apparatus complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The wire end is gripped by the chuck mechanism in its tensioned state before cutting occurs. This preliminary gripping action eliminates the need for complex post-cutting positioning mechanisms, as the wire end is already secured in the correct position before the cutting process begins.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If wire ends are left in random state after cutting, then the process is simple, but automated recognition and pick-up become difficult

Engineering Contradiction:

Improveautomation capabilityVSAvoidwire end position consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The wire end is gripped by the chuck mechanism in its tensioned state before cutting occurs. This preliminary gripping action eliminates the need for complex post-cutting positioning mechanisms, as the wire end is already secured in the correct position before the cutting process begins.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250350175A1Workpiece holding apparatus, winding apparatus, winding processing method, and winding manufacturing method

Publication Date: 2025.11.13 ODAWARA ENG

AI summary

In order to enable positioning of wire ends of the wound wires with a simple configuration, the workpiece holding apparatus includes a plurality of chucks configured to hold a workpiece provided with salient poles (cores), in a state where wires fed from nozzles are wound around the salient poles, by moving in radial direction of the workpiece and coming into contact with the workpiece. Among the plurality of chucks, each first chuck includes a holding part configured to hold a first portion of the corresponding wire located between the corresponding salient pole and the corresponding nozzle, and the wires are cut in a state where their first portions are held.