Stator Winding End Twisting With Radial Backing for Precise Welding
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Solution Overview
Problem
Existing methods for twisting conductor ends in electric machine windings face challenges such as misalignment, electrical arcs, and stress on insulation due to the proximity of conductors, which complicates the welding process and prevents precise guidance of conductors during deformation.
Innovation Solution
An apparatus with a radial backing member and movable teeth is used to guide and deform conductors, maintaining them outside a predetermined circle during twisting, reducing stress on insulation and preventing obstruction during insertion, while minimizing mechanical stress on conductor coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conductor ends are twisted in close proximity to achieve welding alignment, then welding precision is improved, but mechanical stress on insulation and risk of electrical arcs increase
Solution Approach 1:
The patent introduces a radial dimension by positioning the twisting matrix at a distance from the stator/rotor core, allowing conductors to be twisted in a radial plane rather than being constrained to twist in close proximity along the axial direction. This dimensional change enables welding alignment while reducing mechanical stress and arc risk.
Solution Approach 2:
The patent introduces an intermediary guiding structure (the radial backing member with groove) that mediates between the twisting matrix and the conductor ends. This intermediary guides the conductors during twisting, ensuring proper alignment while distributing mechanical stress and preventing direct contact that would cause arcs.
2Manufacturing precision
If conductors are guided precisely during deformation to prevent misalignment, then welding accuracy is improved, but device complexity increases
Solution Approach 1:
The guiding function is segmented into discrete radial backing members positioned at specific locations, rather than requiring a continuous complex guiding structure. Each backing member with its groove provides localized guidance, simplifying the overall device while maintaining precision.
Solution Approach 2:
The patent employs curved or grooved surfaces on the radial backing members that naturally guide conductors through their deformation path. The curved geometry provides continuous contact and guidance without requiring complex mechanical constraints, reducing device complexity while maintaining guidance accuracy.
3Object-affected harmful factors
If conductors are kept outside a predetermined circle during twisting, then insulation stress is reduced, but manufacturing precision may be compromised
Solution Approach 1:
The radial backing member is designed to move radially during the twisting process, dynamically adjusting its position to maintain optimal distance from the conductor ends. This dynamic movement allows conductors to remain outside the predetermined circle during twisting while still achieving precise positioning for welding.
Solution Approach 2:
The groove in the radial backing member is pre-positioned and pre-shaped to guide conductors along the desired deformation path before twisting begins. This preliminary positioning ensures that conductors follow the correct trajectory, maintaining both insulation stress reduction and positioning accuracy throughout the twisting process.
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 apparatus ensures accurate guidance and deformation of conductors, reducing the risk of electrical arcs and misalignment, and minimizes stress on insulation, facilitating precise welding and efficient winding assembly.
Implementation Method 1
a twisting matrix (201) adapted to rotate about an axis (X), comprising at least one pocket (204) suitable for the insertion of a free end (108, 110) of said conductors, wherein during a twisting step, the protruding conductors (102) on the same side are bent towards each other to form the coils of a winding
Implementation Method 2
a radial backing member (300) provided close to said portion of the protruding conductor (102), said radial backing member (300) comprising an inner radial backing surface (302) for said portion of leg (104, 106) protruding from said side of said stator or rotor (114) of an electric machine
Data Source
AI summary
An apparatus for deforming conductors of at least one winding assembly protruding from a side of a stator or rotor of an electric machine is provided. The conductors are arranged with at least one leg inserted into cavities of the stator or rotor, having at least one free end. The apparatus has at least one twisting matrix rotating about an axis and having at least one pocket for insertion of the at least one free end, a radial backing member provided close to the at least one twisting matrix, and in particular close to the at least one pocket on an insertion side of the at least one free end. The radial backing member has an inner radial backing surface for a portion of the at least one leg protruding from the side of the stator or rotor.