Radial Pusher Wire-Twisting Assembly for Springback Control
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Solution Overview
Problem
The springback behavior of electrical wire shanks after deformation in twisting apparatuses compromises the quality of alignments, making it difficult to couple ends of shanks according to predefined quality standards, which can lead to overheating and operational issues in electric machines.
Innovation Solution
An assembly with radial pushers and shoulders is used to temporarily eliminate play between wire end portions and their seats in a ferromagnetic core, ensuring stable alignment and minimizing springback by compacting the wires before twisting, using a method that involves moving pushers from a passive to an active configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the dimensions of the slots of the ferromagnetic core are reduced to minimize springback, then the springback of the shanks is reduced, but the insertion of the shanks into the slots becomes excessively complex or impossible using automatic machines
Solution Approach 1:
The patent applies preliminary action by introducing radial pushers that temporarily eliminate play between the shanks and slot walls before the twisting operation occurs. This pre-positioning of the shanks in a constrained state allows subsequent twisting with minimal springback, while maintaining standard slot dimensions that remain compatible with automatic insertion machines.
Solution Approach 2:
The patent employs dynamics by using movable radial pushers that can transition between an active position (where they constrain the shanks against the slot walls) and a passive position (where they allow free insertion). This dynamic constraint system enables both easy automatic insertion and precise alignment during twisting operations.
2Manufacturing precision
If conventional devices are used to reduce play between slots and shanks, then some alignment improvement is achieved, but the springback remains significant enough to compromise welding quality
Solution Approach 1:
The radial pushers are positioned to eliminate play between the shanks and slot walls before the twisting operation begins. This preliminary constraint ensures that when the twisting apparatus deforms the shanks, the springback is minimized because the shanks start from a pre-constrained position, thereby ensuring reliable alignment for subsequent welding operations.
Solution Approach 2:
The radial pushers act as intermediary elements between the slot structure and the shanks. They temporarily mediate the interaction by providing radial constraint forces that eliminate play, enabling precise alignment during twisting while not interfering with the subsequent welding process.
3Ease of manufacture
If the play between slots and shanks is not reduced, then insertion remains simple, but the springback causes poor alignment quality and potential overheating in the electric machine
Solution Approach 1:
The radial pushers are activated before twisting to preliminarily constrain the shanks in the slots, eliminating play and minimizing springback. This preliminary action maintains simple insertion procedures while ensuring the alignment precision required for reliable operation and preventing overheating issues.
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 assembly achieves optimal and stable alignment of wire ends, reducing springback and ensuring precise coupling, while protecting the insulating layer and maintaining alignment for subsequent welding operations, thus enhancing the operational reliability of electric machines.
Implementation Method 1
each radial pusher (7) being movable in a radial direction between a passive configuration, in which the terminal element (9) is arranged separate from and facing the wire end portions (T) of the wires (A) that protrude from the seats (D) of the ferromagnetic core (C), to an active configuration, in which the terminal element (9) of each radial pusher (7) enters into spaces defined between respective wire end portions (T) of wires (A) that protrude from the contiguous seats (D) of the ferromagnetic core (C) and which are partially accommodated in the contiguous channels (5a, 6a) of the carousel (4), so as to be interposed between the wire end portions (T) of circumferentially contiguous wires (A) until it abuts against the terminal element T of the wire A1 (the one closer to the radial pusher 7), by way of a front (8a) of the respective shoulder (8), so forcing such wire end portions (T) of the wires (A), arranged in respective seats (D) of the ferromagnetic core (C), against the internal, bottom walls (E) of said seats (D), radially compacting them so as to temporarily eliminate their play inside the respective seats (D)
Implementation Method 2
The at least two bushings (5, 6) being usefully configured to be made rotate so as to perform the twisting of the wire end portions (T) of wires (A) that protrude from the seats (D) of the ferromagnetic core (C) and are partially accommodated in the channels (5a, 6a)
Data Source
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AI summary
An assembly (1) for minimizing the springback of wire end portions (T) of electrical wires (A) that are arranged in seats (D) of a ferromagnetic core (C) when they are subjected to twisting. The assembly comprises a twisting apparatus (2) which is provided with a fixed body (3) on which a carousel (4) is mounted so that it can rotate. The carousel (4) comprises at least two bushings (5, 6) which are circular in cross-section and are mutually contiguous, concentric and provided with respective channels (5a, 6a) which are substantially parallel to an axis of symmetry (IV) of the carousel (4), each channel (5a, 6a) defining at least one receptacle configured to partially accommodate at least one respective wire end portion (T) of a wire (A) that protrudes from a seat (D) of a ferromagnetic core (C). The at least two bushings (5, 6) are configured to be made rotate in order to perform the twisting of the wire end portions (T) of wires (A) that protrude from the seats (D) of the ferromagnetic core (C) and are partially accommodated in the channels (5a, 6a). The assembly (1) further comprises a plurality of radial pushers (7) which are arranged circumferentially and are configured to be axially positioned between the ferromagnetic core (C) and the carousel (4). Each one of such pushers (7) is provided with a terminal element (9) and a shoulder (8) contiguous with the terminal element (9). The pushers (7) are moreover movable in a radial direction between a passive configuration, wherein the terminal element (9) is arranged distally from the wire end portions (T) of wires (A) that protrude from the seats (D) of the ferromagnetic core (C), and an active configuration, wherein the terminal element (9) enters into spaces defined between the wire end portions (T) of wires (A) that protrude from the contiguous seats (D) of the ferromagnetic core (C) and are partially accommodated in the contiguous channels (5a, 6a) of the carousel (4), so as to be interposed between the wire end portions (T) of circumferentially contiguous wires (A), and wherein a front (8a) of the respective shoulder (8) abuts against the wire end portion (T) of the wire (Al) that is contiguous with the pusher (7) so as to force the wires (A) that are arranged in a common seat (D) of the ferromagnetic core (C) against a wall (E) of the respective seat (D), radially compacting them so as to temporarily eliminate their play inside the respective seats (D), prior to the step of twisting via rotation of the bushings (5, 6).