Wave Winding Wire-End Stripping by Laser Ablation
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Solution Overview
Problem
Existing methods for stripping wire ends in wave windings face issues such as contamination, complexity, increased cycle times, and inaccuracies due to insulation removal at inappropriate stages, leading to restricted accessibility and potential recontamination.
Innovation Solution
A method involving winding insulated wires on a template, transferring them to a linear magazine, and using laser ablation in defined process windows to remove insulation laterally from protruding wire ends, allowing for easy access and precise stripping without disrupting the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wire ends are stripped and inserted into slot openings for wave winding, then the winding can be assembled, but loose wire ends may remain in the slot openings causing reliability issues
Solution Approach 1:
The wire ends are pre-stripped of insulation before insertion into the slot openings. This preliminary preparation ensures that the conductive portions are exposed and ready for proper electrical contact, preventing insulation from interfering with the connection and avoiding loose wire ends in the slot openings.
Solution Approach 2:
The insulation is extracted or removed from the wire ends through stripping. This extraction of the insulating material allows the conductive wire ends to be properly inserted into the slot openings and establishes reliable electrical connections without insulation interference.
2Productivity
If multiple wire ends are inserted into slot openings, then the wave winding structure is formed, but it becomes difficult to detect and measure whether all wire ends are properly inserted
Solution Approach 1:
Different insulation colors are used to identify different wire ends or phases. This color coding system allows for easy visual detection and verification of whether all wire ends are properly inserted into the slot openings, solving the detection difficulty while maintaining production efficiency.
3Ease of manufacture
If wire insulation is not stripped, then the wiring process is simpler, but electrical connections cannot be established
Solution Approach 1:
The insulation stripping is performed as a preliminary action before the wiring assembly. By removing the insulation in advance, the process ensures that conductive wire ends are properly exposed for electrical connection while maintaining an organized and efficient wiring process.
Solution Approach 2:
The insulation is extracted from the wire ends to expose the conductive material. This extraction is necessary to establish proper electrical connections between the wire ends and the slot openings, ensuring both ease of manufacturing and reliable electrical contact.
Data Source
Figure 1~2
AI summary
The invention relates to a method for stripping wire ends (22) of a wave winding (20), comprising the following method steps: winding a wave winding (20) from parallel, insulated individual wires onto a flat former (100) about a winding axis, with open ends (22) of the individual wires laterally protruding over the former; and removing any insulation from the individidual wires in the region of the wire ends (22).