Stator Winding Conveyor With Rotating Feeder
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Solution Overview
Problem
Existing devices for winding stator or rotor cores have limitations in achieving high productivity due to low rotation rates of the wire guide, which restricts the efficiency of wire deposition and layering, especially for complex core shapes and larger wire diameters.
Innovation Solution
A device featuring a conveyor with a sliding surface that tapers progressively around the core, combined with a rotating wire feeder and alternating motion mechanism, allows for higher winding speeds by distributing wire turns efficiently around the core, enabling faster and more precise winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the wire guide is rotated around the core to perform winding, then the wire can be deposited around the core, but the rotation rate is limited and productivity remains low
Solution Approach 1:
Instead of rotating the wire guide around the core, the invention inverts the approach by keeping the wire guide stationary and rotating the core itself. This allows the wire to be fed linearly through the stationary guide while the core rotates, enabling much higher rotation rates and significantly improving winding speed and productivity.
Solution Approach 2:
The invention replaces the mechanical rotation of the wire guide with a stationary positioning system, and instead uses the rotation of the core combined with linear feed of the wire through the guide. This substitution of the mechanical winding mechanism enables higher speeds while maintaining precise wire deposition.
2Manufacturing precision
If the wire guide is moved around the core to reach complex shapes, then deposition precision improves, but rotation rate decreases and productivity is limited
Solution Approach 1:
The invention inverts the traditional approach by making the core the moving element rather than the wire guide. The core rotates and is positioned to match its complex geometry, while the wire guide remains stationary. This allows precise wire deposition following complex core shapes while maintaining high rotation rates for improved productivity.
Solution Approach 2:
The invention introduces dynamic positioning of the core relative to the stationary wire guide. The core can be dynamically rotated and positioned to match its complex geometry, allowing the wire to be deposited precisely along complex paths while the system operates at high speeds through controlled rotation rather than slow manual guide movement.
3Speed
If a stationary wire guide is used with rotating core, then high rotation rates are achieved, but only simple core shapes can be wound
Solution Approach 1:
The invention makes the positioning system dynamic, allowing the core to be rotated and positioned at various angles and positions during the winding process. This dynamic adjustment capability enables the system to accommodate complex core shapes while maintaining high rotation rates, thus resolving the contradiction between speed and adaptability.
Solution Approach 2:
The stationary wire guide is designed with multi-functionality, capable of accommodating different wire types and diameters, and the system can be programmed to handle various core geometries. This universality allows a single high-speed configuration to serve multiple winding applications with different core shapes, maintaining both speed and versatility.
Data Source
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AI summary
A device for inserting, winding and layering a wire on one or more stator or rotor cores. The device comprises: - a conveyor (2) provided with a sliding surface (3) for the wire (4) to be wound; the sliding surface (3) extends around a main axis (5) and can be arranged around the axis of the stator or rotor core (6) around which the wire (4) is to be wound; and - means (7) for feeding the wire (4) to be wound, which are adapted to dispense the wire (4) on the sliding surface (3) of the conveyor (2). The feeder means (7) can rotate about the main axis (5) with respect to the conveyor (2) in order to deposit turns of wire (4) around the sliding surface (3) of the conveyor (2) and the conveyor (2) can be actuated with an alternating motion along the main axis (5) with respect to the stator or rotor core (6) in order to progressively release the turns of wire (4) around the stator or rotor core (6).