Stator Winding End Turn Forming with Flexible Dies
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Solution Overview
Problem
Existing methods for forming stator windings in dynamoelectric machines face challenges in maximizing conductor packing efficiency within stator slots without damaging insulation, particularly in shaping end turns to promote layer nesting.
Innovation Solution
The use of a plurality of forming die sets, comprising male and female forming dies, allows for the precise formation of end turns and stator slot segments, enabling efficient nesting by sliding the male dies into the female dies to form the desired shapes without damaging the conductor insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional forming methods are used to shape end turns, then the conductor can be formed into basic shapes, but the manufacturing precision and insulation integrity deteriorate due to damage to conductor insulation during the forming process
Solution Approach 1:
The patent applies this principle by using a flexible forming shoe with a contoured surface that contacts the conductor. The forming shoe acts as a flexible forming element that can be pressed against the conductor to shape the end turn without causing insulation damage, as the flexible surface distributes pressure evenly and prevents concentrated stress points that would damage the insulation.
Solution Approach 2:
The forming shoe serves as an intermediary element between the forming force and the conductor. Instead of directly applying forming forces that could damage the insulation, the intermediary forming shoe with its specific contour profile mediates the forming process, allowing precise shape control while protecting the conductor insulation from damage.
2Quantity of substance
If end turns are formed to promote layer nesting, then conductor packing efficiency is improved, but the device complexity increases due to the need for multiple forming die sets
Solution Approach 1:
The patent applies this principle by designing a forming shoe that can be used across multiple forming die sets. The same forming shoe with its specific contour profile can be employed in different positions and configurations to form various end turn shapes, reducing the need for entirely different forming tools and simplifying the overall device complexity while maintaining the ability to achieve precise nesting configurations.
Solution Approach 2:
The forming process is segmented into multiple stations or positions, each with forming die sets that can be configured with appropriate forming shoes. This segmentation allows different sections of the conductor to be formed independently with precise control, enabling complex nested configurations to be achieved through a series of simpler, modular forming operations rather than requiring a single complex forming device.
3Quantity of substance
If multiple layers of slot sections are disposed in each stator slot to maximize fill, then conductor quantity is improved, but manufacturing precision deteriorates due to gaps between layers
Solution Approach 1:
The flexible forming shoe with its precisely contoured surface enables the end turns to be formed with exact dimensions and angles. This flexibility allows the forming process to accommodate variations in conductor properties while maintaining consistent, gap-free nesting between layers, ensuring that multiple layers can be packed tightly together without spaces that would reduce manufacturing precision.
Solution Approach 2:
The patent employs parameter changes by adjusting the contour profile of the forming shoe to control the exact geometry of the end turns. By modifying parameters such as the angle, radius, and length of the formed end turns, the process optimizes how layers nest together, eliminating gaps between layers while maximizing the conductor fill within the stator slots.
Data Source
AI summary
An apparatus and method for forming at least one end turn and at least one stator slot segment of a conductor for a stator of a dynamoelectric machine comprising at least two forming die sets. The forming die sets are disposed having a space substantially equal to a width of the conductor between adjacent die sets and include a female forming die and a male forming die linearly slideable to the female forming die. The die sets are disposed such that both at least one end turn and at least one stator slot segment are formable between the male forming dies and the female forming dies when the male forming dies are sequentially actuated to the female forming dies.