Integrated Flat Wire Stator Twisting for Multi-Layer Insertion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing technologies for processing and producing flat wire motor stators face challenges in accurately inserting and twisting multiple wire layers due to complex structures and operations, leading to inefficiencies and increased difficulty with increasing wire layers.
Innovation Solution
An expanding and twisting mechanism with a movement protection mechanism, an expanding and twisting assembly, and a driving mechanism, which includes gear protection tools, cam followers, cylinders, and a material transfer mechanism, allows for efficient and automatic processing of flat wire motor stators with a simple structure and brief steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate expanding mechanism and twisting mechanism are used, then wire insertion accuracy is improved, but apparatus structure complexity increases
Solution Approach 1:
The patent combines the expanding mechanism and twisting mechanism into a single integrated apparatus. The expanding mechanism includes expanding components that can radially expand wire layers, while the twisting mechanism includes twisting components that can twist the expanded wires. These two functions are merged into one apparatus with a common base, coordinated control system, and shared structural elements, thereby reducing apparatus structure complexity while maintaining wire insertion accuracy through the coordinated action of expanding and twisting components.
Solution Approach 2:
The apparatus is designed with multi-functional components that can perform both expanding and twisting operations. The base structure supports both expanding mechanisms and twisting mechanisms, and the control system coordinates both functions. This universal design allows a single apparatus to perform multiple operations (expanding, twisting, and wire insertion) that would otherwise require separate dedicated devices, thus reducing overall system complexity while maintaining precision.
2Manufacturing precision
If separate expanding and twisting operations are performed, then wire insertion accuracy is improved, but operation steps complexity increases
Solution Approach 1:
The patent implements continuous coordinated operation where the expanding mechanism and twisting mechanism work simultaneously or in closely sequenced steps. The control system coordinates the expanding components and twisting components to operate in a continuous workflow, eliminating idle transitions between separate operations. This continuous action approach maintains wire insertion accuracy while simplifying the operation steps by creating a seamless integrated process rather than discrete separate operations.
Solution Approach 2:
The apparatus is designed to perform preliminary expanding actions before twisting, with the expanding mechanism preparing the wire layers in a predetermined state. The expanding components radially expand the wire layers to a specific configuration that facilitates subsequent twisting operations. This preliminary action ensures that wires are properly positioned and prepared before twisting begins, maintaining insertion accuracy while reducing the complexity of the overall operation sequence.
3Power
If quantity of flat wire layers is increased, then motor power output is improved, but twisting difficulty increases
Solution Approach 1:
The apparatus handles multiple flat wire layers by dividing them into individual layers through the expanding mechanism. The expanding components radially expand each wire layer separately, allowing the twisting mechanism to process them individually or in manageable groups. This segmentation approach enables the system to handle a large total quantity of wire layers (improving motor power output) while managing the complexity of twisting by processing layers in a structured, divided manner rather than as a single complex bundle.
Solution Approach 2:
The expanding mechanism introduces a radial dimension to the wire layer handling process. By radially expanding the wire layers from the center outward, the apparatus creates spatial separation between layers that facilitates easier twisting. This dimensional approach allows multiple wire layers to be managed in three-dimensional space rather than as a flat two-dimensional stack, reducing twisting difficulty while maintaining the ability to process large quantities of wire layers for high power output.
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 solution enables rapid and efficient expansion and twisting of copper wires, increasing production efficiency and the production rate of stators by simplifying the processing steps and ensuring accurate wire insertion.
Implementation Method 1
a cam follower, configured to convert rotational motion into linear motion to drive the expanding head
Implementation Method 2
a driving mechanism, configured to assist the expanding and twisting assembly in completing stator processing, and configured to provide power for movement of a component in the expanding and twisting assembly
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention discloses an expanding and twisting mechanism for and an apparatus for processing and producing a flat wire motor stator. The expanding and twisting mechanism includes: a movement protection mechanism, configured to protect and transport a stator during production; an expanding and twisting assembly, configured to expand, separate, and twist a flat wire of a stator transported by the movement protection mechanism; a driving mechanism, configured to assist the expanding and twisting assembly in completing stator processing, and configured to provide power for movement of a component in the expanding and twisting assembly; and a lower support base, configured to mount the expanding and twisting assembly, to implement processing of the flat wire motor stator fully automatically, and help separate and twist flat wires of a stator by using a simple structure and brief steps, helping increase processing efficiency of the stator.