Rotating Former Winding Device for Electric Machine Stators
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Solution Overview
Problem
Existing methods for producing rotors or stators with distributed wave windings are complex and difficult to automate, requiring large space and precise alignment, making them inefficient and impractical for compact machine integration.
Innovation Solution
A method and device that utilize a shortened rotating former with a transfer device, where the winding is generated with turns displaced alternately and rotated 180°, allowing continuous transfer to a co-rotating rotor or transposing tool, with cams and transposing pins for precise positioning and stabilization, enabling space-saving and automated winding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional methods are used to produce distributed wave windings, then the windings can be placed into stator grooves, but the process becomes complex and difficult to automate
Solution Approach 1:
The winding process is segmented into distinct operational phases: wire feeding, bending at specific angles, forming winding heads, and transferring to the rotor. Each phase is handled by specialized components (wire feed device, bending devices, forming devices, transfer device) that work in sequence, enabling automated production while keeping each component relatively simple and modular.
Solution Approach 2:
The former is designed to rotate dynamically during the winding process, allowing the wire to be laid at different angles and positions automatically. The rotation of the former combined with the coordinated movement of bending and forming devices enables complex winding patterns to be generated through dynamic motion rather than complex static tooling.
2Volume of moving object
If traditional winding methods are used, then windings can be produced, but large space is required
Solution Approach 1:
Multiple functions are merged into a compact integrated device: the wire feed device, bending devices, forming devices, and transfer device are combined in a single winding head assembly. The former serves multiple purposes as both the winding support and the rotating element that generates the wave pattern. This merging enables high productivity within a compact footprint suitable for integration into electric machines.
3Manufacturing precision
If traditional winding methods are used, then windings can be produced, but precise alignment is required
Solution Approach 1:
The winding head assembly is designed to self-align and self-position during operation. The rotating former automatically maintains the correct geometric relationships between wire feeding points, bending points, and transfer points. The coordinated rotation and movement of the integrated components ensure precise alignment is maintained throughout the winding process without requiring external alignment mechanisms or complex setup procedures.
Data Source
AI summary
A method to produce rotors or stators of electric machines having radial grooves into which webs of flat windings having parallel webs and winding heads connecting said webs being pulled, wherein a winding is produced on a rotating, strip-shaped flat former shorter than the winding such that windings are pulled off the former and transferred into a linear transfer device, which transports the windings to a removal position at which the windings are transferred into radial grooves of a rotor or of the transfer tool for transfer into radial grooves of a stator, wherein the former, the transfer device, and the rotor or the transfer tool being jointly rotated about an axis of rotation of the former when rotated to form windings.