Inductive Winding End Alignment With Radial Compaction
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Solution Overview
Problem
Existing methods for aligning conductive elements in inductive windings require long protruding ends for coupling, leading to increased space occupation and vulnerability to faults, as they demand precise positioning and robust clamping, which complicates the manufacturing process and increases the risk of malfunctions.
Innovation Solution
A method and device that utilize alignment and compaction means to clamp conductive elements in a radial direction, allowing for reduced end length protrusion, enabling efficient coupling while maintaining mechanical strength and stability, and allowing for standard or thicker clamping elements without increasing length, thus reducing space occupation and fault risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the free ends of conductive elements are made long to protrude from clamping elements for coupling, then the coupling operation can be performed, but the space occupation of the inductive windings increases
Solution Approach 1:
The invention changes the clamping force parameter by applying a radial compaction force that pushes the free ends together with sufficient force to enable welding coupling. This allows the free ends to be shorter while still achieving reliable coupling, as the radial force compensates for the reduced protrusion length
Solution Approach 2:
The invention separates the alignment function from the compaction function into two distinct operational phases: first tangential alignment aligns the free ends along the tangential direction, then radial compaction applies force in the radial direction to push them together for coupling. This segmentation allows each phase to optimize for its specific purpose, enabling shorter free ends
2Volume of moving object
If the thickness of clamping elements is reduced to minimize space occupation, then the space is optimized, but the clamping elements become more delicate and prone to faults
Solution Approach 1:
The invention uses a radial compaction mechanism that applies force from the center outward in a curved path, distributing the mechanical stress more evenly across the clamping elements. This radial approach reduces stress concentration points that would occur with linear clamping, making thinner clamping elements more reliable
Solution Approach 2:
The invention performs preliminary tangential alignment before applying radial compaction force. This preliminary action positions the free ends in the correct orientation and reduces misalignment stresses, allowing thinner clamping elements to withstand the subsequent compaction force without failing
3Manufacturing precision
If robust clamping is applied to ensure precise positioning for welding, then the positioning precision is improved, but the device complexity increases
Solution Approach 1:
The clamping elements in the invention serve multiple functions: they provide tangential alignment, apply radial compaction force, and maintain positioning during welding. This multi-functionality eliminates the need for separate alignment devices and positioning fixtures, reducing overall device complexity while maintaining precision
Solution Approach 2:
The invention merges the alignment and compaction operations into a single integrated process where the same clamping mechanism performs both tangential alignment and radial compaction. This consolidation reduces the number of separate components and simplifies the device structure compared to using separate alignment and clamping systems
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method and device facilitate the alignment and coupling of conductive elements with reduced space occupation, enhanced mechanical strength, and lower susceptibility to faults, enabling efficient and cost-effective production of inductive windings with improved operational safety.
Implementation Method 1
the melting of the material of the two heads generates a connecting joint
Implementation Method 2
the melting of the material of the two heads generates a connecting joint
Implementation Method 3
mutual welding of the terminal heads of the free ends
Data Source
AI summary
A method for the alignment and the compaction of conductive elements of inductive windings of a ferromagnetic core, in which groups of conductive elements are accommodated beforehand in respective slots of a ferromagnetic core, keeping corresponding free ends of the elements protruding from a terminal opening of each slot, the method includes the following steps: clamping each group of conductive elements in order to align the respective free ends according to a radial direction, using alignment elements; clamping each group of conductive elements in order to compact the respective free ends according to a radial direction, using compaction elements; and removing either the alignment elements or the compaction elements to a distance from the ferromagnetic core that is greater than the operating space occupation of the apparatuses for coupling heads of free ends of each group of conductive elements.