Wave Winding Mat Assembly for Automated Coil Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing coil windings for electrical machines are complex, costly, and difficult to automate, particularly when using wave winding wires, as they require intricate weaving or braiding, which can lead to wire stress and damage.
Innovation Solution
A method and device for producing a winding mat and coil mat using wave winding wires that are bent in a wavy manner, with straight sections and roof-shaped ends, allowing for easy plugging together without intertwining, to form half-wave sections that alternate directionally, enabling efficient assembly and reduced stress on wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wave winding wires are used to produce coil windings, then the coil windings can be formed with good electrical performance, but the production process becomes complex and costly due to required weaving or braiding
Solution Approach 1:
The winding mat is divided into multiple individual wave winding wires that are arranged parallel to each other. Each wire maintains its own wave shape with alternating bending directions, eliminating the need for complex weaving or braiding processes while preserving electrical performance
Solution Approach 2:
Instead of weaving or braiding wires together to form the winding mat, the invention inverts the approach by arranging parallel wave winding wires side by side. The wave shapes are oriented perpendicular to the wire length, creating a functional winding mat through simple placement rather than intricate interlacing
2Ease of manufacture
If wave winding wires are woven or braided together, then the winding mat can be formed, but wire stress and damage occur during the process
Solution Approach 1:
The winding mat consists of multiple independent wave winding wires arranged in parallel. Each wire maintains its structural integrity independently without being subjected to the stresses of weaving or braiding, as they are simply positioned adjacent to each other
Solution Approach 2:
The invention extracts and eliminates the weaving or braiding step from the manufacturing process. By removing this complex interlacing operation, wire stress and damage are prevented while the winding mat is still successfully formed through parallel arrangement of individual wires
3Productivity
If traditional winding methods are used, then coil windings can be produced, but automation is difficult and costs are high
Solution Approach 1:
The wave winding wires are pre-formed with their wave shapes and alternating bending directions before assembly. This preliminary preparation allows for straightforward automated placement and arrangement into the final winding mat configuration, significantly enhancing automation capability
Solution Approach 2:
The invention changes the geometric parameters of the wire arrangement by orienting the wave shapes perpendicular to the wire length and arranging wires in parallel. This parameter change simplifies the assembly process, making it suitable for automated production while maintaining coil winding quality
Data Source
Figure 1
Figure 2~5
Figure 6~7
AI summary
The invention relates to a winding mat in the form of a flat winding and a coil mat formed therefrom for producing a coil winding for an electric machine. In order to be able to automatically mass produce different coil mats also with layer change and conductor change with high reliability, the invention proposes to assemble wave winding wires by insertion to form a winding mat. In order to produce the coil mat, the invention proposes inter alia to assemble two individual mats by insertion.