Spiral Electric Wire Rolling Apparatus for Stator Coil Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for rolling electric wires for stator coils in electric rotating machines face challenges with misalignment due to springback, leading to inaccurate assembly and reduced space factor and magnetic characteristics.
Innovation Solution
A method and apparatus using a rolling apparatus with radially inner, intermediate, and outer pressing members to plastically deform electric wires, ensuring accurate alignment and formation of a spiral shape, preventing misalignment and enhancing magnetic characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electric wires are rolled into spiral shape for stator coil formation, then the stator coil can be assembled with stator core, but misalignment occurs due to springback causing inaccurate assembly and reduced space factor
Solution Approach 1:
The pressing operation is divided into two distinct stages: first pressing to perform preliminary shaping and suppress initial springback, then second pressing to achieve final precise alignment. This segmentation of the deformation process allows each stage to address specific aspects of the alignment problem, preventing the misalignment that would occur with a single pressing operation.
Solution Approach 2:
The first pressing operation serves as a preliminary action that pre-shapes the electric wire and suppresses springback before the final positioning. By performing this preliminary deformation and stabilization step before the second pressing, the system prepares the electric wire in an optimal state for achieving precise final alignment, thereby preventing misalignment issues.
2Manufacturing precision
If electric wires are pressed to extend along the pressing member surface, then alignment is improved, but plastic deformation requires significant pressing force
Solution Approach 1:
The total pressing force requirement is segmented into two pressing operations with different force levels. The first pressing applies a moderate force for preliminary shaping, allowing the electric wire to undergo initial plastic deformation without requiring excessive force. The second pressing then applies a focused force to achieve final precise alignment, reducing the peak force requirement compared to a single high-force pressing operation.
Solution Approach 2:
The pressing process utilizes parameter changes by varying the pressing force magnitude between the two stages. The first pressing uses a lower force parameter for preliminary deformation, while the second pressing uses a higher but more focused force parameter for final alignment. This parameter variation optimizes the balance between achieving necessary plastic deformation and minimizing the overall force requirement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures precise alignment and assembly of electric wires, improving the space factor and magnetic performance of stator coils, thereby enhancing the productivity and efficiency of the stator assembly process.
Implementation Method 1
pressing a first part of the electric wire between the outer surface of the inner pressing member and the inner surface of the intermediate pressing member, thereby plastically deforming the first part to extend along the outer surface of the inner pressing member
Data Source
AI summary
Disclosed is an apparatus for rolling a substantially planar electric wire by more than one turn into a spiral shape. The apparatus includes an inner pressing member having an outer surface, an intermediate pressing member having radially inner and outer surfaces, and an outer pressing member having an inner surface. The inner and intermediate pressing members together press a first part of the electric wire between the outer surface of the inner pressing member and the inner surface of the intermediate pressing member, thereby plastically deforming the first part to extend along the outer surface of the inner pressing member. The intermediate and outer pressing members together press a second part of the electric wire between the outer surface of the intermediate pressing member and the inner surface of the outer pressing member, thereby plastically deforming the second part to extend along the outer surface of the intermediate pressing member.