Wave Winding Wire Stacking With Drop Magazine Geometry Control
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Solution Overview
Problem
Current methods for manufacturing wave winding mats for electrical machine coil windings face challenges in automating the stacking process of meander-shaped wires, leading to deformation, twisting, and increased space requirements, which can impair insulation and make handling difficult.
Innovation Solution
A method and device for stacking wave winding wires using a drop magazine system with guide devices and a workpiece carrier to maintain wire geometry and position, allowing for precise and automated stacking without intermediate handling, using a control unit to manage the process and embossing the winding heads for accurate alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wave winding wires are stacked using conventional automated processes, then productivity is improved, but the wires undergo deformation and twisting which impairs insulation and increases space requirements
Solution Approach 1:
A magazine serving as an intermediary device is introduced between the wire supply and the stacking position. The magazine contains guide devices that maintain the wave winding wires in their original geometry during transfer, preventing deformation and twisting while enabling automated stacking operations.
Solution Approach 2:
The magazine is designed to automatically feed wave winding wires to the stacking position without requiring intermediate manual handling. The guide devices within the magazine self-maintain the wire geometry through their contoured receiving spaces and guide surfaces, eliminating the need for external intervention to preserve wire shape.
2Ease of manufacture
If wave winding wires are handled during stacking, then stacking can be performed, but the wires change geometry and become difficult to handle
Solution Approach 1:
The magazine acts as an intermediary handling system that takes over the wire handling task from manual operations. By providing a dedicated receiving space with guide devices, the magazine simplifies the stacking process while simultaneously improving ease of operation through automated, deformation-free wire transfer.
3Shape
If strong deformation is applied to wires during winding, then winding heads are formed, but insulation is impaired and space requirements increase
Solution Approach 1:
The wave winding wires are pre-formed with their final geometry and insulation intact before being loaded into the magazine. The stacking process then transfers these pre-formed wires without additional deformation, preserving the insulation while achieving the required winding head configuration through precise positioning rather than forceful shaping.
Data Source
AI summary
A method of stacking wave winding wires (wires) for forming a winding mat for a stator coil winding including providing a drop magazine containing a plurality of similar wires in a receiving space, wherein a receiving space contour is configured to the received wires, such that the wires are positioned at a plurality of guide devices at different receiving space boundary locations and guided through the receiving space without changing their geometry, positioning a workpiece carrier having a retaining structure for a winding mat formed of multiple stacked wires in a first transfer position below the magazine and depositing a wire from the magazine at a first position on the workpiece carrier, positioning the workpiece carrier in a second transfer position offset from the first transfer position below the magazine, and depositing a further wire from the magazine at a position offset from the first position on the workpiece carrier.