Wave Winding Device Loose Transport Jaw Elements
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Solution Overview
Problem
Existing wave winding devices face issues with frequent gripping and changing of grippers, leading to potential damage of winding wires and difficulty in producing windings with varying spacings, especially when multiple layers are required for stator core insertion.
Innovation Solution
A wave winding device utilizing loose transport jaw elements with varying groove spacings, which are placed and lifted only once to minimize handling and allow for flexible winding spacing adjustments, along with a transport jaw return device for efficient reuse and a conveying device for continuous processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If grippers are placed several times on the wave winding to transport it, then the winding can be moved in the transport direction, but the winding wire is subjected to frequent gripping and changing which increases the risk of damage
Solution Approach 1:
The transport jaw is divided into multiple independent jaw elements (first transport jaw element, second transport jaw element, etc.) that can be selectively placed and removed. Each jaw element has multiple wire receiving grooves to hold different windings. This segmentation allows the winding to be transported without频繁 repositioning the entire gripper system, reducing handling次数 and damage risk.
Solution Approach 2:
The transport jaw elements act as intermediary components between the mandrel and the windings. Instead of directly gripping and repeatedly positioning grippers on the windings, the jaw elements serve as a stable intermediate structure that can be placed once and used for continuous transport, minimizing direct manipulation of the winding wire.
2Ease of operation
If grippers are used to transport the wave winding, then the winding can be carried in the transport direction, but the same winding spacing is produced which makes it difficult to insert multiple layers into the stator core
Solution Approach 1:
Different transport jaw elements have different groove spacings configured for specific purposes. The first transport jaw element has a first groove spacing suitable for initial transport, while the second transport jaw element has a second groove spacing optimized for stator core insertion. This local differentiation of groove spacing allows the system to adapt to different operational requirements without changing the entire transport mechanism.
Solution Approach 2:
The groove spacing parameter of the transport jaw elements is varied to achieve different winding configurations. By selecting jaw elements with appropriate groove spacings, the system can produce windings with different spacing characteristics suitable for different layers of the stator core, enhancing versatility while maintaining the same transport function.
3Area of stationary object
If a small mold core is used to produce wave windings, then the device size is reduced, but changing mats of any length cannot be efficiently produced
Solution Approach 1:
The transport jaw elements are designed to be movable and replaceable rather than fixed to the mold core. The placement device can position jaw elements at different locations along the transport direction, and jaw elements can be removed and replaced as needed. This dynamic configuration allows a small mold core to produce windings of variable lengths and patterns, maintaining production flexibility despite the reduced core size.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A wave winding device (1) comprises a feeding device (2) that provides at least one winding wire (3) via at least one winding die (7) and transports it in a feeding direction (Y). It further comprises a winding unit (5, 4) that winds the fed winding wire (3) and includes a forming core which is rotatably driven about a rotary axis (P1) and extends in a transport direction (X). The wave winding device (1) includes a wire guiding device (8) which is designed to grasp one or more windings lying on the forming core (4) and guide them in the transport direction.The wire guiding device (8) comprises a plurality of loose transport jaw elements (100), each having a plurality of wire receiving grooves (103), a transport jaw mounting device (6) arranged in the area of the die core (4) and designed to place transport jaw elements (100) onto the winding wire (3) lying on the die core (4), and a transport jaw receiving device (11) designed to receive transport jaw elements (100). The wire guiding device (8) further comprises a transport jaw driving device (8.11, 8.21) designed to engage with the transport jaw elements (100) and move them in the transport direction (X).