Multi-Pole Armature Winding Device with Latch Pawl Mechanism
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Solution Overview
Problem
Conventional winding methods for coils around multi-pole armatures are inefficient, leading to reduced productivity and potential damage to the wire due to complex processes and excessive coil length, which affects motor characteristics.
Innovation Solution
A winding apparatus with a nozzle and latch pawls that move in radial and circumferential directions to efficiently insert wire into slots between magnetic poles, allowing for simultaneous insertion without deforming the wire and increasing winding speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the conventional inserter method is used to wind wire around magnetic poles, then the wire can be inserted into slots, but the process becomes complicated and productivity decreases
Solution Approach 1:
The winding process is segmented into distinct functional components: the nozzle feeds wire to specific positions, the first latch pawl secures wire ends at magnetic poles, and the second latch pawl inserts wire into slots. This segmentation allows each component to perform its function efficiently without requiring complex coordinated movements, thereby increasing productivity while simplifying the overall process control
Solution Approach 2:
The latch pawls serve as intermediary tools between the wire and the slots. Instead of directly inserting wire into slots (which requires precise positioning and risks damage), the latch pawls act as mediators that hold, guide, and facilitate wire insertion. This intermediary mechanism simplifies the winding process by providing a straightforward hold-and-insert operation, improving productivity without increasing device complexity
2Reliability
If the coil is inserted with leeway to avoid damage, then wire damage is reduced, but excessive coil length projects from stator ends and reduces motor characteristics
Solution Approach 1:
The invention replaces the conventional mechanical insertion method (which requires manual positioning and risks wire damage) with a latch pawl-based system. The latch pawls mechanically secure the wire at precise locations and guide it into slots with controlled movements. This mechanical substitution eliminates the need for leeway-based insertion, achieving both wire protection and precise coil length control, thereby improving reliability without sacrificing manufacturing precision
Solution Approach 2:
The latch pawl mechanism changes the insertion parameters by providing controlled, incremental movements rather than single-step insertion. The first latch pawl holds the wire at a predetermined position, and the second latch pawl inserts it into the slot in a controlled manner. This parameter change in the insertion process allows precise coil length control while preventing wire damage, resolving the contradiction between reliability and manufacturing precision
3Manufacturing precision
If the hook and nozzle are moved around the stator periphery to drop wire between slots, then wire can be positioned, but the operation takes too long and winding speed cannot be increased
Solution Approach 1:
The first latch pawl performs preliminary action by securing the wire end at a predetermined position on the magnetic pole before the insertion step. This preliminary positioning ensures accurate wire placement without requiring slow, deliberate movements during the insertion phase. The wire is pre-positioned and held securely, allowing the second latch pawl to quickly insert it into the slot, thereby maintaining manufacturing precision while increasing winding speed
Solution Approach 2:
The latch pawls are designed with dynamic capabilities, allowing them to move between different positions (holding position and insertion position) as needed. The first latch pawl can hold the wire at various magnetic poles, and the second latch pawl can dynamically insert wire into different slots. This dynamic design allows rapid repositioning without sacrificing positioning accuracy, resolving the contradiction between manufacturing precision and productivity by enabling fast, controlled movements
Data Source
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AI summary
A winding apparatus includes a nozzle for feeding a wire to a first end side of a magnetic pole in a winding position, a first latch pawl capable of latching the wire fed from the nozzle, a first latch pawl moving mechanism that moves the first latch pawl from the first end side to a second end side of the multi-pole armature, and a nozzle moving mechanism that moves the nozzle in both the radial direction and the circumferential direction of the multi-pole armature. A width of the first latch pawl in the circumferential direction of the multi-pole armature is set at a width enabling insertion of the wire wound around and bent back by the first latch pawl into slots formed on both sides of one or more of the magnetic poles in the winding position.