Wave Winding Bending Heads for Precise Low-Stress Coil Forming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing wave windings in electrical machines are inefficient in bending wire materials to form the desired geometric contours, often resulting in material stress and requiring complex setups.
Innovation Solution
A device and method utilizing pivotable bending elements with adjustable positions and actuation systems to gently form wave windings by pivoting the bending elements into contact with the wire material, allowing for efficient and flexible production of bends with minimal material stress and compact device design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex bending setups are used to form wave windings, then the geometric contours can be achieved, but the device complexity and material stress increase
Solution Approach 1:
The bending device is divided into multiple independent bending units, each with its own bending element that can be individually actuated. This segmentation allows complex wave winding contours to be achieved through coordinated action of simpler, modular components rather than a single complex bending mechanism
Solution Approach 2:
The bending elements are designed with movable and adjustable characteristics, allowing dynamic adaptation to different wire materials and bending requirements. The actuation system enables real-time control of bending position and geometry, replacing fixed complex mechanisms with flexible dynamic systems
2Productivity
If traditional bending methods are used, then wave windings can be produced, but material stress and production efficiency are reduced
Solution Approach 1:
The traditional mechanical bending system is replaced with an actuation system that provides more precise and controlled force application. This substitution enables gentler bending with reduced material stress while maintaining or improving production efficiency through better control and automation
Solution Approach 2:
The bending process parameters such as force magnitude, application speed, and contact pressure are optimized and dynamically adjusted. This allows the bending operation to be performed with minimal material stress while achieving the required geometric contours efficiently
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and gentle bending of wire materials into wave windings with reduced material stress and compact device design, supporting the production of wave windings with varying lengths and geometric contours.
Implementation Method 1
the bending elements are each pivotably mounted about a first pivot axis and have a first bending head distal to the first pivot axis
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a device and a method for producing a bend in a wave winding for a coil winding of an electrical machine.The device comprises: a first arrangement (1) of first bending elements (2), each of which is pivotably mounted about a first pivot axis (2a), each having a first bending head (2c) distal to the first pivot axis (2a) and being arranged in a first starting position on one side of the wire material (3) after insertion and before bending in the longitudinal direction of the wire material (3); and a second arrangement (6) of second bending elements (7), each of which is pivotably mounted about a second pivot axis (7a), each having a second bending head (7c) distal to the second pivot axis (7a) and being arranged in a second starting position on the opposite side of the wire material (3) after insertion and before bending in the longitudinal direction of the wire material (3).To produce a bend in a wave winding for a coil winding, the device is further configured as follows: the first bending elements (2) are pivotable from the first starting position from one side towards the inserted wire material (3) into a first bending position; the second bending elements (7) are pivotable from the second starting position from the opposite side towards the inserted wire material (3) into a second bending position; and the first and the second bending elements (2, 7) are arranged in the longitudinal direction after the respective pivoting into the first and the second bending positions to form an arrangement of adjacent pivoted bending elements in which the wire material bent to form the wave winding runs around the first and the second bending heads (2c, 7c) and between adjacent bending elements.