Segment Coil Forming Sequence for Slot Insulation Uniformity
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Solution Overview
Problem
The existing method for manufacturing segment coils results in a thin insulation coating on the slot housing portion, leading to a decreased space factor and increased occupation ratio, compromising the insulation properties and efficiency of the coil.
Innovation Solution
A method involving a bending step followed by a cross-section forming step for the coil wire without pre-applied insulation, allowing for optimal insulation coating application post-bending and cross-section forming, ensuring the insulation coating thickness is minimized and evenly distributed, thus enhancing the space factor and insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the cross section forming step is performed on a linear coil with pre-formed insulation coating, then the coil structure is transformed to fit the slot, but the insulation coating thickness decreases and may deteriorate
Solution Approach 1:
The patent applies preliminary action by performing the cross section forming step BEFORE the insulation coating step. The coil wire is first transformed into the desired cross-sectional shape (rectangular, oval, or triangular) to fit the slot, and then the insulation coating is applied to the formed shape. This sequence ensures the insulation coating is applied after the shape transformation, preventing coating thinning or deterioration during forming.
2Reliability
If a thicker insulation coating is applied to the slot housing portion to compensate for transformation, then the insulation property is improved, but the occupation ratio in the slot increases and space factor decreases
Solution Approach 1:
By performing cross section forming before insulation coating, the patent eliminates the need for excessive insulation thickness. The insulation coating is applied to the already-formed shape, ensuring uniform and minimal thickness that provides adequate insulation without occupying unnecessary space in the slot, thereby optimizing the space factor.
Solution Approach 2:
The patent changes the sequence of process parameters (forming before coating instead of coating before forming). This parameter change allows the insulation coating thickness to be optimized for the final shape, ensuring sufficient insulation property while minimizing the occupation ratio and maximizing the space factor in the slot.
3Ease of manufacture
If the insulation coating is applied before bending and cross section forming, then the coil wire is protected during handling, but the coating deteriorates during the forming process
Solution Approach 1:
The patent inverts the conventional sequence by applying insulation coating AFTER bending and cross section forming instead of before. This reversal eliminates the problem of coating deterioration during forming while still providing protection, as the coating is applied to the final shape and remains intact throughout subsequent handling and installation.
Data Source
AI summary
This method for manufacturing a coil includes a cross section forming step for transforming an outer shape of a part to be housed in a slot in a coil wire that has a circular cross section and is not subjected to an insulation coating process, and an insulation step for performing, after the cross section forming step, the insulation coating process on the coil wire after cross section forming.