Stator Winding Guide Mechanism for Small Gap Precision
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Solution Overview
Problem
Existing methods for winding wire around magnetic poles of a stator face challenges when the gap between poles is small, leading to irregular winding and reduced space factor, and require post-processing steps that decrease production efficiency.
Innovation Solution
A winding method and device that uses an index mechanism, nozzle moving mechanism, and guide mechanisms to wind wire regularly around stator teeth, even when the gap is small, by adjusting the nozzle's orientation and using upper and lower portion guides to position and insert the wire directly into the slot, eliminating the need for post-processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the direct winding method is used to wind wire around magnetic poles, then the space factor is improved and regular winding is achieved, but winding cannot be performed when the gap between opposing wires becomes smaller than the nozzle width
Solution Approach 1:
The patent introduces a guide as an intermediary component between the nozzle and the magnetic pole. The guide has a tip portion that can be inserted into the slot between magnetic poles, allowing the wire to be guided into the slot even when the gap is smaller than the nozzle width. This mediator enables the winding process to continue in situations where direct nozzle-to-pole winding would fail.
Solution Approach 2:
The guide is divided into distinct functional portions: a tip portion for insertion into the slot, a wire guiding portion for directing the wire, and a body portion. This segmentation allows each part to perform its specific function effectively, with the tip portion navigating the small gap while the wire guiding portion ensures proper wire placement.
2Adaptability or versatility
If wire is drawn out using a hook and dropped onto the magnetic pole when the gap is too small, then winding can be performed, but the dropped wire easily becomes loose making regular winding difficult
Solution Approach 1:
The guide serves as a continuous intermediary that maintains wire tension and positioning throughout the winding process. Unlike the hook method where wire is dropped and may become loose, the guide continuously supports and directs the wire from the nozzle to the magnetic pole, ensuring regular and consistent winding placement.
Solution Approach 2:
The guide maintains continuous contact with and support for the wire throughout the winding operation. This continuous action prevents the wire from becoming loose or irregularly positioned, unlike discontinuous methods where wire is dropped onto the pole. The guide ensures uninterrupted wire guidance from start to finish of each winding cycle.
3Manufacturing precision
If the stator is provided as a divided core with winding performed on each core before assembly, then the space factor can be improved, but post-processing steps such as core inserting and wire connecting are required
Solution Approach 1:
The guide is designed to be attached to and move with the nozzle itself, making the nozzle self-sufficient for guiding wire into small gaps. This eliminates the need for separate post-processing steps like core assembly and wire connection, as the winding process can be completed directly on the assembled stator in a single operation.
4Manufacturing precision
If the nozzle is moved through the slot between adjacent magnetic poles for winding, then regular winding can be performed, but winding cannot be performed when the gap becomes smaller than the nozzle width
Solution Approach 1:
The guide is segmented into a tip portion for insertion, a wire guiding portion, and a body portion. This segmentation allows the tip portion to extend into the small gap between magnetic poles beyond what the nozzle can reach, enabling the wire to be guided into slots that are narrower than the nozzle width while maintaining regular winding.
Solution Approach 2:
The guide extends the wire path into a different spatial dimension by inserting the tip portion into the slot between magnetic poles. This allows the wire to be positioned in the gap region without requiring the entire nozzle to pass through the narrow space, effectively bypassing the dimensional constraint of the small gap.
Data Source
Figure 1
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Figure 3A~3E
AI summary
A winding method for winding a wire (2) fed from a nozzle (9) onto a stator (1) having a plurality of radially disposed teeth (4) includes a positioning step for positioning the wire (2) fed from the nozzle (9) relative to a tooth (4) while holding the wire (2) using a guide (7, 8) and a wire inserting step for moving the nozzle (9) relative to the stator (1) without passing the nozzle (9) between adjacent teeth (4A, 4B) while the wire (2) is held by the guide (7, 8) such that the wire (2) fed from the nozzle (9) is inserted between the adjacent teeth (4A, 4B).