Segment Coil Bending Timing to Prevent Insulation Damage
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Solution Overview
Problem
Existing methods for bending segment coils in stator manufacturing cause damage to the insulating coating due to contact between adjacent coil end rows during the bending process, requiring special processing of the segment coil or jig shapes.
Innovation Solution
A method and device that twist and bend adjacent coil end rows in opposite circumferential directions with controlled timing differences to avoid strong contact between deformed and thickened portions, using a first and second operation with separate jigs and drive units controlled by a computing unit to synchronize the completion times of the bending operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adjacent coil end rows are twisted and bent in opposite directions during the bending process, then the coil ends are formed into the predetermined shape, but the insulating coating of the segment coil is damaged due to contact between the coil ends
Solution Approach 1:
The patent applies preliminary action by making the first coil end row reach its movement completion position before the second coil end row reaches its movement completion position. This sequential timing arrangement ensures that when one coil end row is being deformed, the adjacent coil end row has not yet completed its deformation, preventing simultaneous contact between the thickened portions of both coil ends and avoiding insulating coating damage.
2Object-affected harmful factors
If special shapes are processed for segment coils or jigs to prevent insulating coating damage, then the insulating coating is protected, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent applies parameter changes by modifying the timing parameter of the bending operation rather than changing the physical shape of the segment coils or jigs. By controlling the sequence in which adjacent coil end rows reach their movement completion positions, the patent prevents insulating coating damage through a process parameter adjustment (timing sequence) instead of requiring complex geometric modifications to the components themselves.
Data Source
AI summary
A method for bending a segment coil includes a first operation of twisting and bending a first coil end row in one circumferential direction and a second operation of twisting and bending, in the other circumferential direction, a second coil end row adjacent to the first coil end row in the radial direction of a stator core. The timing at which the first coil end row reaches the movement completion position through the first operation is made different from the timing at which the second coil end row reaches the movement completion position through the second operation. A device for bending a segment coil performs the method described above.