Stator Coil Manufacturing Using Aligning Members for Precise Wire Positioning
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Solution Overview
Problem
The existing method for manufacturing stator coils with continuous windings faces challenges in maintaining accurate alignment and even intervals of straight portions during the rolling process, leading to low accuracy of alignment and slot occupation ratio, which affects the performance and output of electric rotating machines.
Innovation Solution
A method that involves shaping and assembling electric wires into shaped wires with alternating turn portions, using aligning members to secure superposition and even intervals between straight superposed parts during the rolling process around a core member, ensuring precise alignment and interval consistency in the rolled wire assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the wire assembly is rolled around the core member without aligning members, then the manufacturing process is simple, but the accuracy of alignment of straight portions and evenness of pitches deteriorate
Solution Approach 1:
Aligning members are introduced as intermediary elements during the rolling process. These aligning members temporarily hold and position the straight portions of the wire assembly, ensuring accurate alignment and even pitch distribution as the wire is rolled around the core member. After rolling completes, the aligning members are removed. This mediator approach resolves the contradiction by providing the necessary alignment control without making the rolling process itself complex.
Solution Approach 2:
The aligning members are inserted into the wire assembly before the rolling process begins. This preliminary positioning action ensures that the straight portions are pre-aligned and spaced evenly before the actual rolling occurs, preventing alignment errors from developing during the rolling operation.
2Manufacturing precision
If aligning members are inserted during rolling, then alignment accuracy and pitch evenness improve, but the manufacturing process becomes more complex
Solution Approach 1:
The aligning members serve as temporary intermediary tools that facilitate the rolling process by maintaining proper geometry. They are simple in design (typically just positioning elements) and are inserted and removed easily, minimizing the impact on manufacturing ease while maximizing the improvement in pitch evenness.
3Productivity
If the wire assembly is rolled without alignment control, then productivity is high due to simple process, but slot occupation ratio and machine output decrease
Solution Approach 1:
By performing alignment preparation in advance through inserting aligning members before rolling, the actual rolling process proceeds quickly without requiring complex real-time adjustment mechanisms. This preliminary action ensures that when rolling occurs, the wire assembly is already positioned correctly, maintaining high productivity while achieving the required slot occupation ratio.
Data Source
AI summary
A plurality of shaped wires, which are obtained by shaping electric wires, are assembled to form a wire assembly 47. The wire assembly 47 is then rolled around a core member 6 with aligning members 7 being inserted into spaces 472 formed between adjacent ones of straight superposed parts 471 of the wire assembly 47.