Stator Winding Coil Forming Method with Sequential Bulging and Crank Steps
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Solution Overview
Problem
The existing manufacturing methods for stator winding coils in rotary electric machines are complex and costly, requiring large machining forces and risking damage to insulating coatings due to the simultaneous formation of crank and oblique portions with restricted displacement of conductor wires.
Innovation Solution
A method that forms bulging, oblique, rectilinear, and circular arc portions in dedicated steps, reducing machining forces and simplifying equipment configuration, using a bulging portion forming step, a crank portion forming step, an oblique and rectilinear portion forming step, and a circular arc forming step, to minimize equipment size and costs while protecting the insulating coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If crank portions and oblique portions are formed simultaneously on conductor wires with restricted displacement, then the coil structure is completed in one step, but large machining forces are required making apparatuses bulky and increasing manufacturing costs
Solution Approach 1:
The patent divides the coil formation process into distinct sequential steps: first forming crank portions on conductor wires, then forming oblique portions and rectilinear portions in separate operations. This segmentation allows each forming step to use simpler, smaller apparatuses rather than requiring one large complex apparatus to perform all operations simultaneously, thereby reducing device complexity and cost while maintaining productivity.
2Quantity of substance
If conductor wires with great rigidity are used to handle larger excitation currents, then the current carrying capacity increases, but the machining forces required for shaping increase and insulating coatings are at higher risk of damage
Solution Approach 1:
The patent applies preliminary action by forming the crank portions on the rigid conductor wires first, creating intermediate structures that facilitate subsequent shaping. This preliminary formation of crank portions allows the rigid conductor wires to be gradually shaped through multiple gentler operations rather than one large deformation step, reducing the risk of insulating coating damage while maintaining the current carrying capacity enabled by the rigid wire structure.
3Manufacturing precision
If a pressing member is pressed onto coil end portions from radially outside after winding, then the coil end portions are formed to set curvature, but the apparatus configuration becomes complicated increasing manufacturing costs
Solution Approach 1:
The patent inverts the conventional approach by forming coil end portions through a sequence of localized shaping operations (crank portions first, then oblique and rectilinear portions) rather than applying external pressure from radially outside after winding. This inverted approach achieves the required curvature precision through incremental forming steps using simpler apparatuses, avoiding the need for complex radial pressing equipment.
Data Source
AI summary
A manufacturing method for a stator winding coil includes: a bulging portion forming step that forms a bulging portion on a conductor wire; a crank portion forming step that forms a crank portion on the central portion of the bulging portion; an oblique portion forming step that forms oblique portions on the conductor wire at two ends of the bulging portion; a rectilinear portion forming step that forms rectilinear portions on the conductor wire at opposite ends of the oblique portions from the bulging portion; and a circular arc forming step that forms the oblique portions into a circular arc shape after forming the rectilinear portions.