Stator Conductor Bending with Independent Rotation and Height Control
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Solution Overview
Problem
Existing methods for bending stator windings in electric machines face challenges in precision due to limited space and the resilience of metal conductors, which makes it difficult to achieve the exact bend required for proper connections, especially with current bending machines that cannot independently control rotation and height positioning.
Innovation Solution
A method and device using a conductor coupler that rotates and moves axially to bend conductors, with independent control of rotation and height positioning using servo motors, allowing for precise twisting while accommodating the changing height of conductors during the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If current bending machines are used to bend conductor ends, then the bending process can be performed, but the precision of bending is insufficient due to inability to independently control rotation and height positioning
Solution Approach 1:
The patent applies dynamics by making the height positioning system adjustable and independent from the rotation mechanism. The height positioning device can dynamically adapt to different bending requirements while the rotation mechanism provides angular control, allowing both parameters to be optimized independently for precise bending.
Solution Approach 2:
The bending machine is segmented into independent functional modules: a rotation mechanism for angular positioning and a separate height positioning device for vertical adjustment. This segmentation allows each subsystem to be optimized independently, resolving the contradiction between precision and complexity by providing modular control.
2Manufacturing precision
If conductor ends are bent to required positions, then proper connections can be made, but the conductors spring back toward original position making precise bending difficult
Solution Approach 1:
The patent applies preliminary action by using the height positioning device to pre-adjust the conductor end position before bending occurs. This preliminary positioning compensates for the expected spring-back effect, ensuring that the conductor reaches the desired final position despite its resilient nature.
Solution Approach 2:
The system employs feedback mechanisms where the actual bend position is monitored and compared against the target position. The height positioning device then makes real-time adjustments to compensate for spring-back, ensuring precise final positioning despite the conductor's tendency to return to its original shape.
3Ease of manufacture
If conductor bending is performed in limited space between conductors, then the bending process can be completed, but access to conductors and associated movement is difficult
Solution Approach 1:
The patent applies the nesting principle by designing a compact height positioning device that operates within the limited space between conductors. The device is structured to fit into the constrained environment while still providing full positioning capability, allowing bending operations to proceed easily despite spatial limitations.
Solution Approach 2:
The invention resolves the space constraint by introducing vertical (axial) movement as an additional dimension of adjustment. Instead of requiring horizontal space for positioning, the system uses vertical displacement to achieve the same positioning effect, effectively utilizing the limited available space through dimensional transformation.
Data Source
AI summary
A twisting device comprises at least one conductor coupler configured to engage a plurality of the conductors and at least one drive operably connected to the conductor coupler. The at least one drive is configured to rotate the conductor coupler in order to bend the plurality of the conductors and simultaneously move the conductor coupler in an axial direction relative to the electric machine component. An associated method of bending conductors positioned in a component of an electric machine comprises first engaging a plurality conductors with a conductor coupler. Thereafter, the plurality of conductors are bent by rotating the conductor coupler while simultaneously moving the conductor coupler in an axial direction relative to the component of the electric machine.