Stator Unit Coil Forming for Insulation-Safe End Alignment
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Solution Overview
Problem
Conventional methods for manufacturing unit coils for stators of rotary electric machines are labor-intensive, require skilled labor, and damage the insulating film, leading to deteriorated insulating performance and low productivity.
Innovation Solution
A method and device for manufacturing unit coils that involve winding a conductive wire into an annular shape with stair-like and linear outer shapes to form an intermediate body, followed by bending and aligning coil end portions to prevent insulating film damage, using a specialized winding device with cylindrical shaft members and guide portions to achieve high productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual shaping methods are used to form unit coils, then flexibility in shaping is improved, but productivity is reduced and insulating performance deteriorates due to tool damage
Solution Approach 1:
The patent replaces manual mechanical shaping operations with an automated winding machine that forms unit coils through controlled wire winding and automatic shaping mechanisms. This substitution eliminates the need for manual tools like wooden hammers and spatulas, thereby improving productivity while maintaining shaping precision through automated control systems.
Solution Approach 2:
The winding machine performs preliminary shaping actions during the winding process itself, forming the unit coil geometry and positioning coil end portions before the coil is completed. This preliminary action ensures that the coil structure is pre-configured to prevent overlapping when mounted, eliminating the need for subsequent manual shaping operations.
2Ease of operation
If manual tools are used for shaping unit coils, then shaping capability is improved, but insulating performance deteriorates due to damage of insulating film
Solution Approach 1:
The patent replaces manual mechanical tools with an automated winding machine that uses controlled mechanical fields and positioning mechanisms to shape unit coils. This substitution eliminates direct contact with manual tools that could damage the insulating film, thereby maintaining insulating performance while achieving the required shaping capability through automated precision control.
Solution Approach 2:
The winding machine introduces intermediary positioning mechanisms and guiding structures that facilitate coil shaping without direct manual tool contact. These intermediaries enable precise control of coil geometry and coil end portion positioning, achieving the required shaping capability while protecting the insulating film from damage.
3Ease of manufacture
If conventional winding methods are used, then manufacturing simplicity is improved, but coil end portion alignment is insufficient leading to overlapping when mounted
Solution Approach 1:
The patent applies local quality by creating different structural characteristics in different parts of the unit coil. Specifically, the coil end portions are formed with distinct positioning features and dimensional characteristics that differ from the main coil body, enabling precise alignment when mounted. This local differentiation ensures proper positioning without compromising the overall manufacturing process.
Solution Approach 2:
The winding machine controls specific parameters such as wire tension, winding speed, and positioning coordinates to achieve precise coil end portion alignment. By adjusting these parameters during the winding process, the system ensures that coil end portions are positioned at exact locations that prevent overlapping when the unit coils are mounted in the stator.
Data Source
AI summary
The unit coil is formed by: bending the coil end portions of the intermediate body such that, in a layer in which a length in an axial direction between the coil end portions is large, positions of the coil end portions projecting furthest from the accommodation portions in the axial direction move away from positions of the accommodation portions in the stacking direction, compared to the previous state; and aligning the positions, in the axial direction, of the coil end portions at an inner side of the annular shape, for each of the layers.