Electric Machine Winding Bending Device Segmentation
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Solution Overview
Problem
Current methods for producing winding carriers in electric machines are costly and complex, requiring expensive tools and machinery, which is particularly challenging in the automotive sector where cost-efficient production is essential.
Innovation Solution
A method and device that utilize a laminated core with slots for winding segments, where the segments are inserted, retained, and bent at specific angles using a bending device, allowing for the production of windings with varying bending angles in a simple and cost-efficient manner without the need for expensive equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods are used to produce winding carriers, then manufacturing precision and reliability are maintained, but production cost and device complexity increase significantly
Solution Approach 1:
The bending device is divided into multiple independent bending units, each capable of bending winding segments at different angles. This segmentation allows the system to handle complex winding configurations while keeping each individual bending unit simple and cost-effective, resolving the contradiction between manufacturing capability and equipment complexity
Solution Approach 2:
The bending device is designed with multi-functional bending units that can perform different bending operations on different winding segments. This universality enables a single device to handle various winding configurations and angles, reducing the need for multiple specialized machines and thereby lowering overall production cost and device complexity
2Adaptability or versatility
If conventional bending methods are used for all winding segments, then manufacturing simplicity is maintained, but adaptability to different bending angle requirements is reduced
Solution Approach 1:
The bending device comprises multiple independent bending units, each configured to bend winding segments at different predetermined angles. This segmentation enables the system to accommodate diverse bending angle requirements while keeping each individual bending unit relatively simple, thus achieving adaptability without excessive complexity
Solution Approach 2:
Different bending units are designed with specific local characteristics tailored to their intended bending angle requirements. Each bending unit has optimized geometry and positioning suitable for its specific function, allowing the overall system to achieve high adaptability while each component remains simple and cost-effective
Data Source
AI summary
A method for manufacturing a coil of an electrical machine includes providing a laminated core having a first and a second slot, and inserting a first winding segment in the first slot to a first region having a first end portion and a second winding segment in the second slot to a second area having a second end portion. The method includes adhering the first end portion by inserting in a first recess a bending device and by positioning of a retaining element into a locking position in the first recess, and holding the second end portion by inserting in a second recess of the bender. The method includes bending the first and the second range in a bending direction to a first bending angle. The method also includes releasing the first end portion, and turning the second region in the bending direction to a second bending angle.