Rectangular Wire Coil Head Shaping via Leg Grippers
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Solution Overview
Problem
Existing machines for shaping rectangular wire coil heads suffer from uncontrolled deformation and abrasion due to contact with moulds, and require different moulds for various coil head shapes, leading to defects and inefficiencies.
Innovation Solution
A machine with leg grippers that allow free movement of one leg during the forming process, using head-forming elements to apply controlled deformation to the coil heads, ensuring precise shaping without uncontrolled deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a two-part mould is used to shape the coil head, then the coil head can be formed, but abrasion or other defects of the rectangular wire insulation occur due to inherent contact between the mould portions and the rectangular wire
Solution Approach 1:
The patent removes the mould from the shaping process entirely. Instead of using a two-part mould that contacts the wire, the invention uses a shaping machine with die blocks and forming elements that guide and shape the wire through controlled contact, extracting the harmful mould-contact mechanism while preserving the head-forming function
Solution Approach 2:
The patent introduces die blocks and forming elements as intermediary components between the shaping machine and the wire. These intermediaries transfer the shaping force through controlled contact points rather than through mould cavities, reducing direct harmful contact with the insulation while still achieving precise head formation
2Adaptability or versatility
If different two-part moulds are machined for different coil head shapes, then various coil head shapes can be produced, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent creates a universal shaping machine that can produce different coil head shapes by adjusting die blocks and forming elements. Instead of requiring different moulds for different shapes, a single multi-functional machine with reconfigurable components handles various head shape requirements, reducing device complexity while maintaining versatility
Solution Approach 2:
The patent employs adjustable and reconfigurable forming elements that can be dynamically positioned and configured to create different head shapes. This dynamic adaptability replaces the need for multiple static moulds, allowing the same machine to produce various coil head shapes through controlled movement and positioning of forming components
3Manufacturing precision
If the legs of the coil are restrained during head forming, then controlled deformation can be achieved, but uncontrolled deformation occurs if one leg is fixed while the other moves freely
Solution Approach 1:
The patent divides the coil into segments (first leg, second leg, and head portions) and applies different restraint levels to each segment during forming. By segmenting the control approach, the machine can independently manage the positioning and restraint of each leg, achieving controlled deformation of the head while maintaining overall coil structure stability
Solution Approach 2:
The patent applies different restraint characteristics to different parts of the coil during forming. Specific die blocks and forming elements provide localized restraint at critical points where deformation control is needed, while allowing freedom of movement in other areas, creating a differentiated restraint strategy that ensures both precision and stability
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 machine achieves precisely formed coil heads with controlled deformation, reducing defects and enabling adaptation to different coil head shapes without uncontrolled deformation, improving the shaping process for semi-rigid wire coils.
Implementation Method 1
a first leg-restraining mechanism that is movable relative to the first leg support between a first resting position and a first gripping position that immobilizes the first leg in the first leg support
Implementation Method 2
at least one head-forming element mounted to one of the first and second leg grippers for contacting at least a portion of one of the first and second heads of the wire coil during the at least one actuated movement
Data Source
AI summary
A method for forming the heads of coils made of rectangular wire so that it fits within the slots of the stator of an electric machine. The method includes receiving a coil having unformed first and second heads separated by first and second legs and applying controlled deformation to yield properly shaped heads. Actuators are provided for causing sequential actuated movements of one of the first and second legs to force the head-forming elements into contact with different portions of the first and second heads while allowing selective free movements of the other leg in response to the actuated movements.