Winding Chuck Layout for Accurate Wire End Positioning
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Solution Overview
Problem
Existing wire end processing systems for stator and rotor cores in motors are complex, costly, and inefficient due to the need for multiple air cylinders and additional members to handle randomly bent wire ends, hindering automation and increasing apparatus size and complexity.
Innovation Solution
A workpiece holding device with chucks that position wires in an orderly and tensioned state before cutting, eliminating the need for additional members to handle bent wire ends, using a simple configuration that includes recessed portions and movable pressing members to hold and align wires during winding and cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire ends are handled after cutting using traditional methods, then wire ends can be secured, but apparatus size and complexity increase due to multiple air cylinders and additional members
Solution Approach 1:
The wire is gripped and positioned in an orderly, tensioned state before cutting occurs. The holding member secures the wire at a predetermined position prior to the cutting process, ensuring that after cutting, the wire end remains properly positioned without requiring complex post-cutting handling mechanisms.
Solution Approach 2:
The holding member serves multiple functions: it grips the wire during winding, positions the wire in an orderly state before cutting, and maintains wire end positioning after cutting. This multi-functional approach eliminates the need for separate mechanisms for each operation, reducing apparatus complexity.
2Reliability
If multiple air cylinders and additional members are used to handle wire ends, then wire ends can be secured, but manufacturing cost increases
Solution Approach 1:
The holding member performs multiple operations (gripping, positioning, and securing wire ends) with a single mechanism, eliminating the need for multiple air cylinders and additional members. This reduction in component count directly lowers manufacturing costs while maintaining reliable wire end handling.
3Device complexity
If wire ends are left in random state after cutting, then no additional positioning mechanism is needed, but automated handling becomes difficult
Solution Approach 1:
The wire is positioned in an orderly, tensioned state before cutting, and the holding member maintains this positioning through the cutting process. This preliminary positioning ensures that after cutting, the wire end is already in a predictable, organized state that facilitates automated handling without requiring complex post-cutting positioning mechanisms.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
In order to enable positioning of wire ends of the wound wires with a simple configuration, the workpiece holding apparatus includes a plurality of chucks configured to hold a workpiece (8) provided with salient poles (cores) (8a), in a state where wires (W1, W2, W3) fed from nozzles (N1, N2, N3) are wound around the salient poles (8a), by moving in radial direction of the workpiece (8) and coming into contact with the workpiece (8). Among the plurality of chucks (14), each first chuck (14C, 14D, 14E) includes a holding part configured to hold a first portion of the corresponding wire (W1, W2, W3) located between the corresponding salient pole (8a) and the corresponding nozzle (N1, N2, N3), and the wires (W1, W2, W3) are cut in a state where their first portions are held.