Flat Copper Wire Stator Coiling with Adjustable Guidance
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Solution Overview
Problem
Existing flat copper wire stator wire coiling devices for hairpin permanent magnet synchronous motors are inefficient and labor-intensive, as they require manual winding of hairpin-shaped copper wire, which hinders continuous operation and mass production.
Innovation Solution
A flat copper wire stator wire coiling device with a tooling conveying mechanism, a winding mechanism, and guiding portions that include a wire routing and guiding system with adjustable components to facilitate continuous and effective winding of flat copper wire, utilizing a manipulator for positioning and a rotating assembly with variable diameters to secure the wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual winding of flat copper wire is used, then the existing device structure is simple, but the processing efficiency is low and labor intensity is high
Solution Approach 1:
The wire routing portion and wire guiding portion are designed to automatically guide and route the flat copper wire through the winding process without manual intervention. The wire body conveys tooling automatically, and the sliding mechanisms self-adjust to maintain wire tension and positioning, enabling continuous automatic winding operation
Solution Approach 2:
The winding device is divided into distinct functional modules: tooling conveying mechanism with wire body, winding mechanism with rotating assembly, wire routing portion with sliding components, and wire guiding portion. Each module performs a specific function and can operate independently, allowing for efficient automated wire winding while maintaining manageable system complexity
2Productivity
If continuous winding operation is implemented, then productivity increases, but the wire may come off during winding
Solution Approach 1:
The wire routing portion and wire guiding portion are designed to slide along the left-right direction dynamically adjusting their positions during the winding process. This dynamic adjustment ensures continuous wire guidance and prevents wire dislodgement while maintaining continuous operation capability
Solution Approach 2:
The sliding mechanisms of the wire routing and wire guiding portions respond to wire tension and positioning feedback during winding, automatically adjusting their positions to maintain proper wire alignment and prevent wire from coming off during continuous operation
3Adaptability or versatility
If fixed diameter winding assembly is used, then the structure is simple, but it cannot adapt to different wire winding requirements
Solution Approach 1:
The rotating assembly is designed with variable inner and outer diameters that can be adjusted dynamically. The insertion pieces can be positioned at different locations on the sleeve to change the effective winding diameter, allowing the same winding mechanism to handle different wire specifications and winding requirements without structural modification
Solution Approach 2:
The winding mechanism with adjustable diameter capability serves multiple functions: it can wind different sizes of flat copper wire, accommodate different winding patterns, and adapt to various stator core configurations. This multi-functionality is achieved through the adjustable insertion pieces and sliding mechanisms that provide versatility without requiring multiple dedicated winding devices
Data Source
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AI summary
The present invention discloses an effective flat copper wire stator wire coiling device, relating to the technical field of hairpin motors. The stator wire coiling device includes a tooling for arranging a flat copper wire, a winding mechanism for winding the arranged flat copper wire, a flat copper wire conveying mechanism and a tooling conveying mechanism. The tooling conveying mechanism is configured to convey the tooling to the winding mechanism. The flat copper wire conveying mechanism is configured to convey, to the winding mechanism for winding, the flat copper wire arranged on the tooling conveyed to the winding mechanism. In the present invention, through cooperation between the tooling conveying mechanism and the flat copper wire conveying mechanism, the arranged flat copper wire can be conveyed into the winding mechanism for winding.