Stator Wire Mat Z-Bending and Twisting

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Solution Overview

Problem

Existing methods for producing electrical machine components, such as stators with wire mats, face challenges in reducing bending radius and minimizing insulation layer damage, leading to potential short circuits and increased copper usage.

Innovation Solution

A method involving Z-shaped bending and twisting of flat wires before installation, where wires are arranged in a specific order and deflected to reduce bending stress on the insulation layer, and a device incorporating tensioning and twisting mechanisms to facilitate this process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If straight bending of flat wires is performed without twisting, then the manufacturing process is simple, but the bending radius is large causing insulation layer damage and potential short circuits

Engineering Contradiction:

Improvebending process simplicityVSAvoidinsulation layer integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The wire is twisted in sections before bending is performed. This preliminary twisting action reduces the bending radius required during subsequent bending operations, thereby preventing insulation layer damage while maintaining manufacturing feasibility

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The wire is divided into multiple sections along its length, with alternating sections twisted in opposite directions. This segmentation allows different parts of the wire to have different twist states, optimizing bending characteristics at various locations while maintaining overall structural integrity

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If traditional wire arrangement is used, then the manufacturing process is straightforward, but copper usage is excessive

Engineering Contradiction:

Improvewire arrangement simplicityVSAvoidcopper usage

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

Wires are swapped in pairs at specific positions before the bending process. This preliminary repositioning allows for more efficient wire routing and reduces the total length of wire required, thereby minimizing copper usage while keeping the manufacturing process manageable

Inventive Principle:

Principle #10Preliminary action

3Reliability

If wires are twisted in sections before bending, then the bending radius is reduced and insulation damage is minimized, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveinsulation layer integrityVSAvoidtwisting and bending process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The twist direction and degree are varied in different sections of the wire. By changing these parameters locally, the wire achieves optimal bending characteristics in each section, reducing the need for complex external twisting devices while maintaining reliability

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP3427372B1Manufacturing method for a stator

Publication Date: 2022.06.22 GROB WERKE & K G

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AI summary

The invention relates to a method for the production of a component of an electric machine, such as, for example, a stator, comprising a wire mat which is made of wire, preferably a flat wire, characterized by the following steps: aligning the wire, twisting the wire in at least some sections about its longitudinal axis, z-shaped angling of the wire, winding the wire, in particular winding the wire helically onto a carrier, transferring the wire mat thus obtained onto a mounting tool.