Rotary Machine Terminal Forming via Segmented Roller and Bending Unit
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Solution Overview
Problem
The existing manufacturing method for rotary electric machines damages the surface of crossover lines due to high sliding friction when forming terminal parts, and reducing curvature to prevent damage compromises the reliability of terminal part formation.
Innovation Solution
A manufacturing device with a separate insertion roller for forming crossover lines and a bending unit for forming terminal parts, where the bending unit has a greater curvature than the insertion roller, and a guide member to support the coil lead line, reducing sliding friction and enabling reliable terminal part formation without damaging the crossover lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the curvature of the disk portion is made comparatively large to reliably form terminal parts, then the terminal parts can be formed accurately, but the surface of the crossover lines is damaged due to high sliding friction
Solution Approach 1:
The invention divides the forming process into two separate operations: (1) inserting the coil lead line into the accommodating groove using the outer circumferential surface of the disk portion, and (2) forming the terminal part by pressing the coil lead line between the outer circumferential surface of the disk portion and a pressing member. This segmentation allows each operation to be optimized independently, resolving the contradiction between terminal part accuracy and crossover line surface integrity.
2Object-affected harmful factors
If the curvature of the outer circumferential surface of the disk portion is made comparatively small to suppress damage to the surface of the crossover lines, then the surface damage is reduced, but the terminal parts cannot be formed reliably
Solution Approach 1:
The invention introduces a pressing member as an intermediary element to perform the terminal part forming operation. The pressing member works in conjunction with the outer circumferential surface of the disk portion to press the coil lead line, enabling reliable terminal part formation without requiring the disk portion's outer circumferential surface to have high curvature, thus preventing surface damage to the crossover lines.
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 allows for reliable formation of terminal parts while minimizing damage to the crossover lines, ensuring accurate and efficient manufacturing of rotary electric machines by reducing sliding friction and maintaining the integrity of the crossover lines.
Implementation Method 1
a comparatively large sliding friction occurs between the coil lead line and the outer circumferential surface of the disk portion
Implementation Method 2
a bending unit configured to perform a bending process to bend the coil lead line by coming into contact with the coil lead line
Data Source
AI summary
A manufacturing method for a rotary electric machine is equipped with an insertion roller having an outer circumferential surface configured to contact a coil lead line in such a manner that the coil lead line is inserted into accommodating grooves of an insulator, a roller support section that rotatably supports the insertion roller, and a bending unit that performs a bending process to bend the coil lead line by coming into contact with the coil lead line so as to form a terminal part.