Split Die Wire Rod Forming for Variable Cross-Section Accuracy
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Solution Overview
Problem
Existing methods for manufacturing wire rods with varying cross-sectional shapes are inefficient, leading to increased tact time and reduced productivity due to the need for frequent adjustments of forming rollers.
Innovation Solution
A manufacturing method and apparatus using split dies with shape-changing surfaces to pressure-form element wires into wire rods with multiple cross-sectional shapes in the longitudinal direction, allowing for high-accuracy and high-speed production of composite trapezoidal wires for motor coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If roll forming is performed using four forming rollers each movable in a direction perpendicular to a rotation axis while changing the interval between the forming rollers, then a composite trapezoidal wire can be manufactured, but the tact time increases and productivity deteriorates
Solution Approach 1:
The invention applies dynamics by making the forming rollers movable in the axial direction of the wire rod. The forming rollers can be positioned at different locations along the axial direction to correspond to different cross-sectional shapes required at different positions of the wire rod. This dynamic positioning capability allows the system to adapt to varying forming requirements without stopping or changing roller intervals, thereby maintaining high manufacturing speed while achieving precise cross-sectional shape control.
Solution Approach 2:
The invention transitions from controlling cross-sectional shapes by changing roller intervals (radial dimension) to controlling cross-sectional shapes by moving rollers along the axial direction (axial dimension). This dimensional shift allows multiple cross-sectional shapes to be formed along the length of the wire rod in a single continuous passing, eliminating the need to stop and reposition rollers radially between different shape formations, thus dramatically improving productivity.
2Adaptability or versatility
If the position of each forming roller is changed during manufacturing of one conducting wire, then different cross-sectional shapes can be achieved, but the manufacturing process becomes slower
Solution Approach 1:
The invention implements preliminary action by pre-positioning multiple forming rollers at different axial locations before the wire rod passes through. Each forming roller is already positioned to create its specific cross-sectional shape. As the wire rod moves through the forming section, it sequentially passes through each pre-positioned roller, which immediately imprints the corresponding cross-sectional shape. This eliminates the need to stop and reposition rollers during manufacturing, thereby reducing tact time while maintaining the ability to produce various cross-sectional shapes.
Solution Approach 2:
The invention ensures continuity of useful action by enabling the wire rod to pass through all forming rollers in a single continuous motion without stopping. The forming rollers are arranged along the axial direction, allowing the wire rod to be continuously formed with different cross-sectional shapes in sequence. This continuous forming process eliminates idle time between different shaping operations, significantly reducing the total manufacturing time while maintaining shape variety.
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
This approach enables the accurate and rapid formation of wire rods with varying trapezoidal cross-sectional shapes, enhancing torque density and productivity by eliminating the need for roller position changes, thus improving motor performance.
Implementation Method 1
pressure-forming the element wire by moving the plurality of split dies in a direction of narrowing the forming space
Data Source
AI summary
Provided is a manufacturing method of a wire rod for forming a coil, the manufacturing method including the steps of: placing an element wire in a forming space surrounded by a plurality of split dies; and pressure-forming the element wire by moving the plurality of split dies in a direction of narrowing the forming space. In the step of pressure-forming the element wire, at least one of the plurality of split dies is moved, and the plurality of split dies each having a surface that changes in shape in a longitudinal direction of an element wire to pressure-form the element wire into the wire rod having a plurality of different cross-sectional shapes in the longitudinal direction.