Core Winding Method for Arch-Like Stator Using Convex Trajectory
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Solution Overview
Problem
Conventional core winding methods face challenges in achieving high positional accuracy and increased facility and manufacturing costs due to the need for complex nozzle movements and larger operation ranges, especially when dealing with joined or integrated cores, which restrict the nozzle's operation range and require additional steps and jumper wires.
Innovation Solution
A core winding method that uses a general-purpose winding machine moving in x-axis, y-axis, and z-axis directions to wind conductive wire on a core with an arch-like yoke portion by drawing a convex-shaped trajectory from the tooth end portion towards the yoke portion, allowing for aligned winding in a bow-like area using an insulator with a winding frame and base portions, reducing the need for complex nozzle movements and minimizing jumper wire length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a conventional winding method is used with an arch-like yoke portion, then the area for storing conductive winding is increased, but the nozzle cannot approach the tooth portion closely resulting in low positional accuracy
Solution Approach 1:
The core is divided into multiple divided cores arranged in a circular shape, with gaps between adjacent divided cores. This segmentation allows the nozzle to wind conductive wire on each divided core separately, avoiding interference with the arch-like yoke portion while maintaining high positional accuracy on the tooth portions.
Solution Approach 2:
An insulator is introduced as an intermediary component between adjacent divided cores. The insulator includes a winding frame portion that guides the conductive wire and a base portion that fills the gap between divided cores, enabling the nozzle to operate with high positional accuracy without interfering with the yoke portion.
2Manufacturing precision
If a mechanism for inclining the nozzle in θ axis direction is added, then aligned winding in bow-like area is achieved, but the facility size and cost increase
Solution Approach 1:
The core is divided into multiple divided cores with gaps between them, eliminating the need for a complex θ-axis inclination mechanism. The nozzle can perform aligned winding on each divided core using only x-y-z axis movements, significantly simplifying the facility while maintaining winding precision.
Solution Approach 2:
The insulator with its winding frame portion acts as an intermediary that enables aligned winding without requiring nozzle inclination. The winding frame guides the conductive wire properly on the divided core surface, achieving precise winding alignment using only standard three-axis nozzle movements.
3Productivity
If multiple divided-type cores are set with distance between them, then continuous winding on multiple tooth portions is enabled, but the jumper conductive wire length and assembly steps increase
Solution Approach 1:
The insulator's base portion is designed in advance to fill the gaps between divided cores, creating a compact arrangement. This preliminary design minimizes the distance between adjacent divided cores, thereby reducing the jumper conductive wire length required for continuous winding while maintaining productivity.
Solution Approach 2:
The insulator serves multiple functions: it provides electrical insulation between divided cores, fills the gaps to minimize distance, guides the conductive wire through its winding frame portion, and supports continuous winding across multiple tooth portions. This multi-functionality reduces both jumper wire length and assembly steps.
Data Source
AI summary
In a method for winding a core having an arch-like yoke portion, a tooth portion, and a tooth end portion by revolving a nozzle for feeding a conductive wire, when winding is performed in a bow-like area surrounded by an inner circumferential arc of the yoke portion and the chord thereof, upon winding on an end surface of the core, the nozzle moves so as to draw a convex-shaped trajectory proceeding from the tooth end portion side toward the yoke portion side with reference to the chord of the bow-like area, and upon winding on a side surface of the core, the nozzle returns from the yoke portion side to the tooth end portion side with reference to the chord of the bow-like area, and then moves along the side surface of the core.