Wave Winding Mat Insertion Using Radial Wire Separation
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Solution Overview
Problem
Existing methods for inserting wave winding mats into electrical machine rotors or stators face challenges such as internal stress, wire damage, and mechanical stress due to the tension in the wires, especially when multiple layers are involved, leading to potential damage during the insertion process.
Innovation Solution
A method and device that utilize radially protruding wire separating elements and a pressing-in device with a contact surface to guide and press the wire sections into gaps between pole teeth, allowing for controlled insertion without damaging the wires, and optionally using a rotating and radially moving pressing-in device to minimize stress and ensure proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical separation and pressing devices are used to insert wave winding mat into rotor or stator, then the wire sections can be guided into gaps, but the internal stress of the winding mat causes wire elements to move relative to each other and can be damaged by metal projections
Solution Approach 1:
The method performs preliminary actions by first introducing the wave winding mat into the rotor or stator before the pole teeth are assembled, and by pre-positioning the wire sections between winding overhangs. This preliminary arrangement allows the wire sections to be correctly positioned before final assembly, preventing damage that would occur if forcing were required during final insertion.
Solution Approach 2:
The pole teeth are segmented into individual components that can be assembled around the already-positioned wire sections. This segmentation allows the wire sections to be placed first, then the pole teeth are fitted around them, eliminating the need to force wire sections through tight spaces and preventing damage from metal projections.
2Adaptability or versatility
If multiple layers of wave winding mat are inserted into adjacent slots, then the electrical component can achieve required performance, but the mechanical stress within the winding mat increases from layer to layer
Solution Approach 1:
Multiple layers of wire sections are pre-positioned between the winding overhangs before the pole teeth are assembled. This preliminary multi-layer arrangement allows each layer to be correctly positioned without excessive stress, as the pole teeth are then fitted around all layers simultaneously rather than forcing each layer through tight spaces sequentially.
Data Source
Figure 1~2
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Figure 7
AI summary
A method for inserting a wave winding mat (2) into the rotor or stator of an electrical machine, in particular into a stator lamination stack (1), comprises the following steps: i) providing a wave winding mat (2) formed from one or a plurality of wave windings (2c); ii) providing a rotor or stator (1) to be fitted with the wave winding mat (2), which has a plurality of pole teeth (1a) arranged circumferentially along the inner or outer surface of the rotor or stator (1) and spaced apart by gaps (1b); iii) inserting the wave winding (2) by successively arranging wire sections (2a) located between the winding heads (2b) of the wave winding mat (2) into the gaps (1b). Before step iii), wire singulation elements (3a) projecting radially over the pole teeth (1a) are arranged on an end face of the rotor or stator (1).In the area of the winding heads (2b) of the wave winding mat (2), an indentation device (4), in particular designed as a forming skid, is positioned. The rotor or stator (1) and the indentation device (4) are moved relative to each other. The indentation device (4) has a contact surface (4a) along which sections of the winding wires of the wave winding mat (2) slide, are separated by the wire singulation elements (3a), and, as a result of the relative movement of the rotor or stator (1) and the indentation device (5), are pressed into the spaces (1b).