Winding Apparatus for Dynamo Electric Machine Cores
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Solution Overview
Problem
Existing methods for winding coils of dynamo electric machines with wire conductors of high thickness face issues with maintaining correct tension, leading to wire bending and incorrect positioning, which compromises the stratification and filling of slots.
Innovation Solution
The apparatus includes a wire dispenser arm with a rotating trajectory and separate, coplanar guide portions protruding from the second and third wire guides to close passageways, ensuring the wire conductor maintains tension and is correctly positioned around the radial poles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a wire dispenser arm rotates about radial poles to dispense wire conductors, then the winding process can be automated and coils can be formed, but the wire conductor loses correct tensioning and bends when it has great thickness
Solution Approach 1:
The patent introduces an intermediary device (the passageway with tensioning elements) between the wire dispenser arm and the wire guide to maintain wire tension. This intermediary structure prevents direct loss of tensioning by providing a controlled path that maintains mechanical constraint on the thick wire conductor during the automated winding process.
Solution Approach 2:
The patent replaces the simple mechanical rotation of the wire dispenser arm with a more complex mechanical system that includes tensioning elements and controlled passageways. This substitution maintains precise mechanical control over thick wire conductors that cannot be adequately controlled by simple rotation alone.
2Ease of operation
If wire guides are positioned to form passageways for wire conductors, then the wire can be guided along the pole, but thick wire conductors bend and lose tension in the passageway
Solution Approach 1:
The passageway itself acts as an intermediary structure that provides controlled support for the wire conductor. By designing the passageway with specific geometric constraints and tensioning elements, the system maintains wire tension while still allowing the wire to be guided along the pole during the winding operation.
Solution Approach 2:
The patent modifies the geometric parameters of the passageway and wire guide positioning to accommodate thick wire conductors. By adjusting parameters such as passageway width, curvature radius, and tensioning point locations, the system maintains adequate tensioning for thick wires while preserving the guidance function.
3Device complexity
If the wire conductor is allowed to move freely from the second wire guide to the first wire guide, then the winding process is simpler, but the wire cannot be correctly stretched and positioned
Solution Approach 1:
The controlled passageway serves as an intermediary constraint that prevents completely free movement of the wire conductor. It provides a defined path with tensioning elements that maintain wire stretch, while still allowing sufficient flexibility for the winding operation to proceed with manageable complexity.
Solution Approach 2:
The patent introduces controllable parameters into the wire path geometry, such as adjustable tensioning points and constrained curvature in the passageway. These parameter changes enable adequate wire tension control without requiring overly complex active control mechanisms, maintaining a balance between device complexity and manufacturing precision.
Data Source
AI summary
Apparatus (1) and method for winding coils (B) of a wire conductor (W) around respective radial poles (10c) of a core (10) of a dynamo electric machine component. The apparatus (1) comprises a wire dispenser arm (11) which rotates about a radial pole (10c) at a time to dispense the wire conductor (W) forming the turns (S). A first wire guide (32) is, furthermore, provided positioned at a first axial end (A) from the radial pole (10c) being wound and moved along a moving direction (132a, 132b) parallel to the radial direction (110c) of the radial pole (10c) to form a respective coil (B). A second and a third wire guide (36, 37) are, furthermore, provided positioned respectively, in a first and in a second slot (10a, 10b) adjacent to the radial pole (10c) being wound at opposite sides. The second and the third wire guides (36, 37) are positioned with respect to the first wire guide (32) in such a way to form at least a respective passageway (38a, 38b, 38′a, 38′b) for the wire conductor W. The apparatus (1) comprises, furthermore, at least a first and a second guide portion (35a, 35b, 35′a, 35′b) coplanar to each other in order to close, at least partially, the, or each, passageway (38a, 38b, 38′a, 38′b) during winding of the radial pole (10c).