U-shaped Winding Element Shaping Tool
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Solution Overview
Problem
Existing methods for forming U-shaped winding elements for electric rotation machines often result in displacements during the shaping process, leading to a winding head that is axially longer than desired.
Innovation Solution
A method involving a setting tool with recesses and a gripping element with teeth that presses an engagement contour into the rod sections, allowing for form-fitting gripping and controlled rotation to prevent displacement, including the use of sliding bevels to exert radial forces and ensure precise alignment and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If holding down or pressing down is used to hold the U-shaped winding elements in the shaping tool, then the winding elements can be retained in position, but displacements still occur resulting in an axially longer winding head
Solution Approach 1:
The holding mechanism is segmented into multiple independent gripping elements distributed around the shaping tool. Each gripping element can independently engage with the winding element, providing distributed holding force that prevents displacement while maintaining manufacturing precision.
Solution Approach 2:
The gripping elements are positioned and configured before the winding element is inserted into the shaping tool. This preliminary arrangement ensures that the gripping elements are ready to immediately engage and secure the winding element, preventing any displacement during the shaping process and achieving the desired axial length precision.
2Manufacturing precision
If the U-shaped winding element is held fixed during shaping, then manufacturing precision is improved, but the device complexity increases due to additional gripping mechanisms
Solution Approach 1:
The gripping elements serve multiple functions: they hold the winding element in position during shaping, apply controlled pressure to prevent displacement, and can be repositioned or adjusted for different winding element sizes. This multi-functionality reduces the need for separate mechanisms, thereby limiting the increase in device complexity while maintaining high manufacturing precision.
Solution Approach 2:
The gripping elements are designed to be movable and adjustable rather than fixed, allowing them to adapt to different winding element geometries and positioning requirements. This dynamic capability enables precise positioning without requiring a completely rigid and complex tool structure, thus balancing manufacturing precision with acceptable device complexity.
Data Source
AI summary
Method for forming at least one U-shaped winding element (10) for an electromagnetically excitable core (11) of an electric rotation machine (12), wherein the U-shaped winding element (10) has a first rod section (13) and a second rod section (15) which are connected by an arcuate connection section (16), wherein an inner tool part (23) having at least one recess (29) in the region of its outer circumference is provided, and an outer tool part (26) having at least one recess (30) in the region of its inner circumference is provided, and at least the U-shaped winding element (10) is inserted into the inner tool part (23) and the outer tool part (26) such that one rod section (13) is inserted into a recess (29) of the inner tool part (23), the other rod section (15) is inserted into a recess (30) of the outer tool part (26), and such that the inner tool part (23) and the outer tool part (26) are rotated with respect to one another about the axis of rotation (36), wherein in that context the at least two rod sections (13, 15) are moved away from one another, wherein, prior to the at least two rod sections (13, 15) being moved away from one another, a gripping element (50) having a tooth (53) is moved toward a rod section (15), which is gripped by means of a tooth (53).