Stator Winding Head Twisting with Cam-Guided Radial Gap Control
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Solution Overview
Problem
The existing methods for twisting the winding head of a stator face challenges in preventing shorting of conductor ends due to friction-induced coating stress and the difficulty in arranging isolation paper between conductor rows.
Innovation Solution
A method and device that utilize a hollow cylindrical stator core with a winding core and cam structure to twist and bend conductor ends, creating a radial gap by guiding the conductor ends over a sliding surface, thereby reducing the risk of shorting and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If isolation paper is placed between conductor rows to prevent shorting, then electrical insulation is improved, but the arrangement process becomes difficult and time-consuming
Solution Approach 1:
The patent removes the isolation paper from the system entirely by creating sufficient radial gap between conductor rows through cam-guided twisting. This eliminates the need for additional insulation materials and simplifies the process while maintaining electrical insulation through physical separation alone.
Solution Approach 2:
The cam structure acts as an intermediary tool that creates and maintains the radial gap between conductors during twisting. Instead of using isolation paper as a passive barrier, the cam actively shapes the spatial relationship between conductors to prevent contact and shorting.
2Productivity
If conductor ends are twisted closely together, then productivity is improved, but the risk of shorting increases due to coating stress and friction
Solution Approach 1:
The cam structure preliminarily establishes the radial gap between conductor rows before the twisting action begins. This pre-positioning ensures that even at high twisting speeds, sufficient clearance exists to prevent coating damage and shorting, allowing productivity to increase without compromising reliability.
Solution Approach 2:
The cam serves as a mediating element that controls the spatial relationship between conductors during twisting. It ensures optimal clearance is maintained throughout the twisting process, enabling high-speed operation while preventing harmful contact between conductor coatings.
3Reliability
If radial gap between conductors is enlarged to prevent shorting, then reliability is improved, but the space factor of the slot is reduced
Solution Approach 1:
The patent creates a dynamic solution where the radial gap is temporarily enlarged only during the twisting operation using the cam structure. After twisting is complete, the conductors return to their normal compact arrangement in the slot, maximizing space factor while still achieving the necessary clearance to prevent shorting during the critical twisting phase.
Solution Approach 2:
The cam structure temporarily utilizes the radial dimension to create clearance between conductor rows during twisting. This dimensional adjustment is transient and localized only to the twisting zone, allowing shorting prevention without permanently reducing the effective space factor of the slot for conductor placement.
Data Source
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AI summary
The invention relates to a method and a twisting device for twisting a winding head of a stator (10), wherein during a twisting process of an end section (42) of conductors (26, 28) of the stator (10), extending over a first end face (14) of a stator core (12), a distance of the end section (42) of the conductors (26, 28) to each other in radial direction of the stator core (12) is at least partially enlarged. For widening the radial gap between the end sections (42) of the conductors (26, 28) a winding core (64) comprising at least one cam (70) protruding in radial direction of the winding core (64) is arranged on the stator core (12) in such a way that during the twisting process at least the end section (42) of the first conductor (26) slides of the cam, bending and/or necking the end section (42) of the first conductor (26) in radial direction outwardly.