Plug-In Wave Winding Mat for Automated Coil Assembly
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Solution Overview
Problem
Existing methods for producing coil windings in electric machines using wave winding wires are complex, costly, and difficult to automate, particularly for profile wires with non-round cross-sections, leading to inefficiencies and reliability issues.
Innovation Solution
A winding mat and coil mat design that utilizes wave winding wires with roof-shaped winding heads, allowing for easy assembly through plugging rather than interlacing, enabling efficient, automated production and improved reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wave winding wires are interlaced to form winding mats, then the structural stability and electrical connectivity are improved, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The winding mat is divided into modular sections with standardized plug-in interfaces. Each section can be manufactured independently and assembled through simple plugging operations, eliminating the need for complex interlacing processes while maintaining structural integrity through standardized connection geometries.
Solution Approach 2:
Standardized plug-in connection elements serve as intermediaries between wire sections. These connectors provide both mechanical support and electrical connectivity without requiring complex interlacing operations, simplifying the manufacturing process while ensuring reliable connections.
2Quantity of substance
If traditional wave winding methods are used for profile wires, then the conductor filling is optimized, but the automation difficulty and production time increase
Solution Approach 1:
Winding mats are pre-assembled with optimized conductor arrangements and plug-in connections before installation. This preliminary preparation allows for automated manufacturing of the mats themselves, while the actual installation process is simplified to straightforward plugging operations, significantly reducing production time without compromising conductor filling optimization.
3Adaptability or versatility
If wave winding wires are used instead of sword windings, then the flexibility and adaptability are improved, but the manufacturing precision and automation capability deteriorate
Solution Approach 1:
The invention standardizes key geometric parameters of the wave winding wires and plug-in connections. By defining precise parameters for wire dimensions, bending radii, and connector geometries, the system maintains the flexibility and adaptability of wave windings while enabling automated manufacturing through consistent, repeatable parameters that can be controlled by manufacturing equipment.
Data Source
AI summary
A winding mat for forming a coil winding of a component of an electric machine has a first wave winding wire and a second wave winding wire. Each wave winding wire has two straight wire sections and two winding heads bent in opposite directions. The first wave winding wire is plugged to a second wave winding wire to join the first and second wave winding wires. A first section of the first wave winding wire crosses a first section of the second wave winding wire at a first cross point. A second section of the first wave winding wire crosses a second section of the second wave winding wire at a second cross point on the first wave winding wire. The first and second cross points are located between ends of respective first winding heads of a first wave section and a second wave section.