Wave Winding Coil Conductor Forming Device
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Solution Overview
Problem
The existing methods for manufacturing wave winding coils result in twists at the apex parts of folded conductors, leading to variations in shape and reduced workability, especially during automated processes.
Innovation Solution
A conductor forming device with a restrainer having grooves that limit the width of folded conductors, preventing twists and ensuring uniform formation of wave winding coils by arranging fold parts in parallel at predetermined intervals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple unit wires are folded simultaneously to form turning parts, then productivity is improved, but twists occur at apex parts causing variations in shape
Solution Approach 1:
A restrainer with grooves is introduced as an intermediary device between the folding mechanism and the conductors. The grooves act as guide structures that receive and constrain the apex parts of turning parts during simultaneous folding, preventing twists while maintaining high productivity
Solution Approach 2:
The grooves in the restrainer are designed to automatically align with and constrain the apex parts of turning parts as they are formed. The structure self-regulates the positioning and orientation of multiple conductors during simultaneous folding without requiring additional active control mechanisms
2Ease of manufacture
If the width of folded conductors is not limited, then ease of manufacture is improved, but twists occur reducing workability
Solution Approach 1:
The restrainer applies localized width limitation only at the apex parts of turning parts where twists occur, rather than constraining the entire conductor. The grooves provide precise local control at critical locations while leaving other portions of the conductors free to be formed
Data Source
AI summary
A conductor forming device which folds a group of conductors in thickness directions, the group of conductors including a plurality of conductors having straight parts, includes a restrainer provided with a plurality of grooves in which fold parts of the conductors each consisting of at least two unit wires are fitted and which limit a width of each of the conductors to a predetermined distance, when the conductors each consisting of the at least two unit wires are to be folded.