Segmented Twisting Jigs for Coil Segment End Portions
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Solution Overview
Problem
The existing method for twisting coil segments in electrical rotating machines suffers from low accuracy due to varying protrusion lengths of segment end portions, leading to biased twisting characteristics and complex power supply line connections, resulting in decreased reliability and quality of the machines.
Innovation Solution
A coil segment processing method that divides the twisting process into multiple steps using a smaller number of twisting jig units, each corresponding to specific layers, allowing for precise adjustment and alignment of segment end portions to achieve uniform twisting accuracy across all layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple twisting jigs are concentrically arranged to simultaneously twist segment end portions of multiple layers, then productivity is improved, but manufacturing precision deteriorates due to biased twisting characteristics from varying protrusion lengths
Solution Approach 1:
The patent divides the multiple layers into different groups, with each group twisted by a dedicated twisting jig. Instead of using one jig for all layers, the patent segments the twisting operation so that each jig handles only the layers it can twist accurately, eliminating the bias caused by varying protrusion lengths across different radial positions.
Solution Approach 2:
The patent assigns different twisting characteristics to different jigs based on their radial positions. Each twisting jig is optimized for the specific protrusion length characteristics of the layers it serves, allowing each local twisting operation to have the appropriate quality rather than forcing a uniform approach on all layers.
2Ease of manufacture
If twisting jigs of adjacent layers are rotated in opposite directions to twist segment end portions, then twisting effectiveness is improved, but device complexity increases due to synchronization requirements
Solution Approach 1:
The patent segments the twisting operation into independent group operations, where each twisting jig handles a specific group of layers. This segmentation eliminates the need for complex synchronization mechanisms between adjacent jigs, as each jig operates independently on its assigned layers without requiring coordinated rotation with neighboring jigs.
3Productivity
If segment end portions with different protrusion lengths are twisted synchronously, then productivity is improved, but manufacturing precision deteriorates due to biased rotation amounts
Solution Approach 1:
The patent segments layers into groups based on their protrusion length characteristics, with each group assigned to a twisting jig optimized for that group's characteristics. This allows simultaneous twisting of multiple layers while maintaining precision, as each jig operates within its optimal rotation range rather than forcing a compromise rotation amount on all layers.
Solution Approach 2:
The patent applies different twisting parameters to different radial positions. Each twisting jig uses rotation amounts and speeds appropriate for the local protrusion length characteristics of its assigned layers, rather than applying a uniform twisting parameter across all layers with varying protrusion lengths.
Data Source
AI summary
The innermost first segment layer and the second segment layer adjacent thereto in a radial direction are twisted using a twisting jig unit including an inner twisting jig and an outer twisting jig, then the twisting jig unit is replaced with another twisting jig unit including an inner twisting jig and an outer twisting jig, and the third segment layer and the fourth segment layer adjacent thereto are twisted, and then the twisting jig unit is replaced with still another twisting jig unit including an inner twisting jig and an outer twisting jig, and the fifth segment layer and the sixth segment layer adjacent thereto are twisted.