Wave Winding Wire Stacking With Drop Magazine Geometry Control
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Solution Overview
Problem
Existing methods for producing wave winding mats for electrical machine coil windings face challenges in maintaining wire geometry and preventing deformation, leading to inefficiencies and increased space requirements due to twisting and severe deformation of wires during the sword winding process.
Innovation Solution
A stacking method and device that utilize a drop magazine with guided receiving spaces and a workpiece carrier to precisely position and stack wave winding wires without changing their geometry, using a separating device and slider to maintain wire shape and prevent deformation, allowing for automated and reliable production of wave winding mats with varied geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sword winding process is used to produce winding mats, then coil windings can be manufactured, but wires are subject to severe deformation and twisting which impairs insulation and increases space requirements
Solution Approach 1:
The wave winding wires are pre-bent into the desired meandering shape before the stacking process. This preliminary shaping allows the wires to be stacked in their final configuration without requiring severe deformation during assembly, thereby preserving insulation and reducing space requirements while maintaining manufacturing capability
Solution Approach 2:
The winding mat is constructed by stacking individual wave winding wires separately rather than forming them all at once through sword winding. This segmentation allows each wire to be individually shaped and positioned, preventing collective deformation and twisting that occurs in traditional processes
2Extent of automation
If automated processes for weaving or braiding bent wires are used, then wave winding mats can be produced, but the processes are complex and time-consuming
Solution Approach 1:
Instead of weaving or braiding wires through complex automated mechanisms, the invention inverts the approach by stacking pre-shaped wave winding wires vertically. This simplifies the automated process from complex lateral manipulation to straightforward vertical deposition, reducing device complexity while maintaining automation
Solution Approach 2:
The wires are pre-bent into wave shapes before automation, eliminating the need for complex real-time bending mechanisms during the automated stacking process. This preliminary preparation allows simple automated handling and stacking operations
3Adaptability or versatility
If wave winding wires are stacked with offset positions, then varied wire geometries can be accommodated, but positioning precision becomes more challenging
Solution Approach 1:
The magazine and workpiece carrier feature localized guiding structures and positioning elements at specific locations. These local features ensure precise positioning even when wires are stacked at offset positions, allowing varied wire geometries to be accommodated without compromising overall stacking precision
Solution Approach 2:
The system allows variation in stacking parameters such as horizontal offsets and vertical positions while maintaining precision through controlled adjustment mechanisms. This enables adaptation to different wire geometries while preserving manufacturing precision through parameter control
Data Source
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AI summary
To reliably automate the stacking of wave winding wires (10, 10a-10f) to form a winding mat (12) for a coil winding of a stator, the invention proposes a stacking method comprising the following steps: providing at least one magazine (14, 14a, 14b) designed as a drop magazine, which contains several identical wave winding wires (10) in a receiving space (18), wherein the contour of the receiving space (18) is adapted to the received wave winding wires (10) so that the wave winding wires (10) are positioned on several guides (20) at different locations on the boundary of the receiving space (18) and guided through the receiving space (18) without changing their geometry; positioning a workpiece carrier (22) which is equipped with a holding structure (24) for a winding mat formed from several stacked wave winding wires (10, 10a-10f). is equipped with a winding mat (12),in a first transfer position below the at least one magazine (14, 14a, 14b) and depositing a wave winding wire (10) from the at least one magazine (14, 14a, 14b) at a first position on the workpiece carrier, positioning the workpiece carrier (22) in a second transfer position offset from the first transfer position below the at least one magazine and depositing a further wave winding wire (10) from the at least one magazine (14, 14a, 14b) at a position on the workpiece carrier (22) offset from the first position.