Simultaneous Coil Segment Forming Apparatus
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Solution Overview
Problem
The existing methods for forming coil segments in copper wires for dynamoelectric machines are time-consuming as they typically form segments one at a time, rather than simultaneously.
Innovation Solution
An apparatus with multiple forming structures that can move along an axis and be actuated to form multiple coil segments simultaneously, using on-axis and off-axis actuators to clamp and shape the wire into a linear configuration, allowing for simultaneous formation of multiple coil segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If coil segments are formed one at a time using a rotating barrel device, then the forming process is simple and reliable, but the productivity is low and the process is time-consuming
Solution Approach 1:
The forming apparatus is segmented into multiple independent forming structures (first, second, third, and fourth forming structures) that can simultaneously form multiple coil segments. Each forming structure includes forming protrusions that contact the wire at different positions, enabling parallel formation of multiple segments along the wire length.
Solution Approach 2:
Multiple forming structures are combined into a single integrated apparatus with a common actuating device. The forming structures are arranged along the wire axis and can be simultaneously actuated to close onto the wire, merging the functions of multiple sequential operations into one simultaneous operation.
2Productivity
If multiple forming structures are used to form coil segments simultaneously, then the productivity increases, but the device complexity increases
Solution Approach 1:
The actuating device serves multiple functions by simultaneously actuating all forming structures. This single multi-functional device can open and close multiple forming structures in unison, reducing the need for separate actuators for each forming structure and managing the complexity of coordinating multiple independent devices.
Solution Approach 2:
The forming structures are designed to be movable rather than fixed, allowing them to open and close dynamically during the forming cycle. The forming protrusions can contact the wire to form segments and then retract, enabling the apparatus to handle continuous wire processing with multiple segments formed in sequence along the wire.
3Reliability
If the wire is held firmly by forming structures during simultaneous segment formation, then slippage is prevented, but work hardening may occur
Solution Approach 1:
The forming structures apply holding force locally at specific contact points (forming protrusions) rather than along the entire wire length. This localized holding minimizes the total force applied to the wire, reducing work hardening while maintaining sufficient grip to prevent slippage during the forming operation.
Solution Approach 2:
The forming structures engage the wire periodically during the forming cycle - closing to hold and form segments, then opening to release. This periodic engagement allows the wire to be held firmly only when necessary for forming, minimizing cumulative work hardening while ensuring reliable holding during critical forming moments.
Data Source
AI summary
Disclosed is an apparatus for forming a wire to include coil segments useable in a dynamoelectric machine, the apparatus including a plurality of forming structures simultaneously moveable along an axis into a coil segment forming configuration, with at least a number of the plurality of forming structures being configured to hold a wire, and at least one actuating device associated with at least a number of the plurality of forming structures and configured to simultaneously move the number of the plurality of forming structures into the coil segment forming configuration.