Winding Device for Generator Stator Coils
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Solution Overview
Problem
The existing methods for fabricating stator coils for generators and motors are inefficient due to the need for separate fabrication and electrical connection of inner and outer coils, which increases manufacturing processes and can lead to overlapping coil ends, affecting efficiency and miniaturization.
Innovation Solution
A winding device and method that uses an inner and outer winding core to continuously fabricate track-shaped coils with different coil end parts by rotating the cores with a pair of looping posts to wind wire around them, allowing for continuous production of coils with varying lengths without the need for separate fabrication and electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If inner and outer coils are separately fabricated, then manufacturing flexibility is improved, but manufacturing process complexity increases and production time is doubled
Solution Approach 1:
The patent combines the fabrication of inner and outer coils into a single continuous winding process. The winding device winds the wire in one continuous operation to form both the inner coil and outer coil with different lengths, eliminating the need for separate fabrication processes and subsequent electrical connections.
Solution Approach 2:
The patent segments the coil fabrication process by using a single winding device that can independently control the winding parameters for inner and outer coils. The device creates distinct coil sections with different lengths within one continuous winding operation, allowing flexibility while maintaining process simplicity.
2Device complexity
If a single coil shape is used for inner and outer coils, then manufacturing process is simplified, but coil end overlap occurs and device size increases
Solution Approach 1:
The patent applies local quality by giving different lengths to the inner and outer coils while fabricating them in a single continuous process. The winding device controls the wire winding parameters locally for each coil section, creating optimal coil dimensions for each position without requiring separate fabrication processes.
Solution Approach 2:
The patent uses dynamic control during the continuous winding process to adjust coil parameters. The winding device can dynamically modify winding parameters mid-process to create inner and outer coils with different lengths, preventing overlap and optimizing device size while maintaining manufacturing simplicity.
3Volume of moving object
If coil side parts are inserted into multiple slots, then space factor is improved, but manufacturing complexity increases due to separate coil fabrication and connection
Solution Approach 1:
The patent merges the fabrication of multiple coils that will be inserted into different slots into a single continuous winding process. The winding device produces inner and outer coils with different lengths in one operation, eliminating the need for separate fabrication and electrical connection processes while enabling multi-slot insertion for improved space factor.
Data Source
AI summary
A winding device includes a winding core configured to take up a wire, wherein the winding core includes an inner winding core configured to be rotated by a rotating part and an outer winding core configured to surround the inner winding core and rotate together with the inner winding core.