Segment Coil Fastening Prevents Wire Separation
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Solution Overview
Problem
Segment coils formed by assembling element wires face challenges in maintaining connection at coil end portions when bent, as the element wires tend to come apart due to stress differences during the bending process, making electrical connection difficult.
Innovation Solution
A manufacturing method that involves bundling and twisting element wires to form a stranded wire, followed by rolling into a rectangular conductor, and fastening the wires at the coil end positions before bending to prevent separation during the formation of segment coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If segment coils are bent to connect coil end portions, then electrical connection between coils is enabled, but element wires in the coil end portions come apart
Solution Approach 1:
The patent applies preliminary action by fastening the element wires at the coil end portions before the bending process. This pre-fastening ensures that when the segment coil is later bent to enable electrical connection, the element wires remain securely bound and do not come apart, thus resolving the contradiction between achieving electrical connection and maintaining wire integrity
Solution Approach 2:
The patent applies preliminary anti-action by introducing a fastening mechanism that counteracts the separating force generated during bending. The fastening creates a restraining force that opposes the tendency of element wires to come apart, allowing the bending operation to proceed while maintaining wire integrity
2Productivity
If element wires are bundled to form rectangular conductor, then manufacturing efficiency is improved, but element wires separate during bending
Solution Approach 1:
The patent applies preliminary action by performing the fastening operation at the coil end portions before the bending step. This timing ensures that the element wires are secured while the conductor is still in its rectangular form, maintaining both manufacturing efficiency and preventing wire separation during subsequent bending operations
Data Source
AI summary
A manufacturing method for a segment coil according to the invention includes forming an assembled wire by bundling a plurality of element wires, forming a stranded wire by twisting the assembled wire, forming a rectangular conductor by rolling the stranded wire, and forming a segment coil by cutting the rectangular conductor into a given length and bending the cut rectangular conductor. Before the rectangular conductor is bent, the plurality of element wires is fastened at a position where the coil end portion of the segment coil is formed.