Wave Winding Wire Bending Synchronization via Linear Guide
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Solution Overview
Problem
Existing wave winding manufacturing devices for coil windings of electrical machines face challenges in precisely bending wires into meandering shapes with straight sections and roof-shaped heads, due to synchronization issues between mold elements, leading to deformation and increased complexity in the bending process.
Innovation Solution
A wave winding manufacturing device with a linear guide mechanism and interchangeable mold elements, utilizing a converter mechanism to synchronize rotational movements and a pressing force introduction device to maintain support during bending, ensuring precise alignment and reduced springback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If forming elements are rotated and moved together to bend wire into wave shape, then wave winding heads are formed, but synchronization between forming elements is lost and wire deformation occurs
Solution Approach 1:
A linear guide mechanism serves as an intermediary component that coordinates the movement of multiple forming elements. The guide ensures that all forming elements move together by the same amount while rotating in opposite directions, maintaining synchronization throughout the bending process and preventing wire deformation.
Solution Approach 2:
The forming elements are designed to rotate dynamically in opposite directions while moving linearly together. This dynamic configuration allows the wire to be bent into the desired wave shape while maintaining precise control over the forming elements' relative positions, ensuring both head formation and straight section alignment.
2Shape
If multiple forming elements are used to create meandering shape, then wave winding wire is formed, but device complexity increases
Solution Approach 1:
Multiple forming elements are merged into a coordinated system where adjacent elements rotate in opposite directions. This combination allows the creation of complex meandering shapes while the shared linear guide mechanism simplifies the overall control system, reducing device complexity despite the multiple forming elements.
3Shape
If forming elements are moved closer together during bending, then wire is formed into desired shape, but synchronization is lost
Solution Approach 1:
The linear guide mechanism acts as a mediator that maintains synchronization between forming elements even as they move closer together during the bending process. The guide ensures equal displacement for all elements, preserving process reliability throughout the forming operation.
4Manufacturing precision
If straight wire sections are held firmly during bending, then parallelism is maintained, but device complexity increases
Solution Approach 1:
The linear guide mechanism serves multiple functions simultaneously: it guides the movement of forming elements, maintains their synchronization, and ensures the parallelism of straight wire sections. This multi-functionality achieves high manufacturing precision without requiring additional separate systems, thereby avoiding increased device complexity.
Data Source
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AI summary
The invention relates to devices (10) and methods for producing wave winding wires for a coil winding of an electric machine via flat winding, wherein a row of shaping elements (14.1, 14.2), each having a holder (16) for holding a straight wire section (100) of a wire (18) to be bent (18) and a bending mould (20) for shaping a wave winding head region between the straight wire sections (100), are moved in a linear manner relative to one another on a linear guide mechanism (12) and are rotated about a respective axis of rotation (22), in order to form a meandering wave winding wire with straight wire sections and chevron-shaped wave winding heads in between from the wire (18) held in the holders (16) by rotating neighbouring shaping elements (14.1, 14.2) in opposite directions with their axes of rotation (22) converging. In order to improve the flexibility and/or process safety, according to one aspect of the invention, a change in spacing of linear guides (26, 28, 34) of the linear guide mechanism is to be converted into the rotational movement of the shaping elements (14.1, 14.2). According to a second aspect of the invention, a bending of the wire ends (96, 98) of the wire is carried out before the meandering bending of the wave winding wire in order to, in particular, easily fix the wire (18) for bending.