Rotor Winding Apparatus Sleeve Wire Fixation
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Solution Overview
Problem
Existing winding devices result in unwanted wire losses and complex disposal processes, leading to additional costs and malfunctions in automated winding processes, as fixed wire sections cannot be reused and must be discarded.
Innovation Solution
A device with displaceable inner and outer sleeves allows for angular and axial fixation of the wire, preventing lateral slippage and enabling precise wire positioning, which reduces wire residues and simplifies the winding process by allowing the wire to be pulled back and fixed without overhang, using a non-positive connection that encloses the wire without jamming it.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire is fixed to a clamp or wrapping pin, then the wire can be secured for winding, but the fixed wire section cannot be reused and must be disposed of as leftover wire
Solution Approach 1:
The invention enables recovery of the wire by using a displaceable sleeve system that allows the wire to be pulled back completely after winding. The sleeve moves from a clamping position to a release position, enabling the wire end to be extracted and reused for the next winding operation, thus eliminating wire disposal and recovery costs
2Reliability
If wire is fixed with a clamp or wrapping pin, then the wire can be secured, but complex disposal processes are required and malfunctions occur in automated winding processes
Solution Approach 1:
The displaceable sleeve system automatically performs the wire release function through its own displacement mechanism. When the sleeve is displaced from the clamping position, the wire is automatically released and can be pulled back through the same sleeve path, eliminating the need for separate disposal operations or additional release mechanisms
3Manufacturing precision
If wire is clamped between outer sleeve and formation, then lateral slippage is prevented, but wire overhang occurs requiring shortening and disposal of remainder
Solution Approach 1:
The invention transforms the static clamping structure into a dynamic system where the outer sleeve can be displaced relative to the formation. This dynamic displacement allows the wire to be clamped securely during winding, then released and pulled back completely after winding, eliminating wire overhang and enabling full wire utilization
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
This solution significantly reduces material losses and simplifies the manufacturing process by ensuring the wire is accurately positioned and securely fixed, minimizing wire overhang and enabling efficient reuse, thus reducing waste and operational complexity.
Implementation Method 1
the wire is enclosed in that the outer sleeve, together with the formation, encloses the wire on the circumferential side, but without jamming it
Implementation Method 2
the angular position of the wire is fixed relative to the formation by means of the outer sleeve
Implementation Method 3
the wire is then frictionally fixed in the second position, in particular clamped, and can thus be loaded by the tensile force occurring during the subsequent winding
Data Source
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AI summary
The invention relates to an apparatus (1) and to a method for winding a part (2), in particular a rotor, held in a receptacle (3) with a wire (8). For this purpose, the part (2) is pivoted into a predetermined angular position in relation to a winding nozzle (7) by means of the receptacle (3) and is then moved in relation to an outer sleeve (10) until the wire (8) is enclosed between a hook-shaped formation (11) and the outer sleeve (10) such that it can move exclusively in the direction of its wire longitudinal axis. In the next step, the wire (8) can therefore be drawn back until the wire (8) touches the formation (11) without any protrusion. Finally, the part (2) is moved in relation to an inner sleeve (12) until the wire (8) is fixed in a force-fitting manner between the formation (11) and the inner sleeve (12). In this way, undesirable residual wire is avoided in optimum fashion such that both material losses are reduced and the manufacturing method is substantially simplified.