Electric Motor Winding Mat Forming Without a Winding Blade
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing winding mats for electric motors face challenges in mechanical stress on conductors, limited flexibility in configuring the winding mat, and difficulties in adapting the length and pitch of the winding process, leading to inefficiencies and increased material expenditure.
Innovation Solution
A method and device that eliminates the use of a winding blade by employing a receiving device and shaping tools movable in a Cartesian coordinate system to form winding heads and bars, allowing flexible configuration and reduced mechanical stress on conductors, with the ability to vary pitch and produce winding mats of any length and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a winding blade or plug-in board is used to produce winding mats, then the winding process can be standardized, but the conductors are subjected to high mechanical stress and the process lacks flexibility in adapting to different lengths and configurations
Solution Approach 1:
The invention extracts and eliminates the winding blade or plug-in board from the winding process. Instead of winding conductors around a rigid template, the method feeds conductors directly to a receiving device that forms winding heads and bars without mechanical constraints, thereby removing the source of mechanical stress while maintaining standardized production through controlled feeding and forming operations
Solution Approach 2:
The invention introduces dynamic adaptability by allowing the receiving device to form winding heads and bars from freely fed conductors without fixed geometric constraints. The process can adapt to different conductor lengths, pitches, and configurations by adjusting the forming parameters of the receiving device, enabling standardized production with flexible adaptation to various motor designs
2Device complexity
If a winding blade is used with fixed dimensions, then the winding process is simplified, but the ability to produce winding mats of different lengths and shapes is limited
Solution Approach 1:
The receiving device is designed with dynamic adjusting capabilities that allow it to form winding heads and bars with variable dimensions. The device can adapt to different conductor lengths, pitches, and winding patterns by modifying its forming parameters, thereby achieving versatility in producing various winding mat configurations without requiring multiple specialized devices
Solution Approach 2:
The receiving device serves multiple functions: it receives conductors, forms winding heads, creates bars, and adapts to different winding configurations. This multi-functional design replaces the need for specialized winding blades for each configuration, simplifying the overall device while maintaining high adaptability to different motor designs and winding requirements
3Ease of manufacture
If the template length corresponds to the winding mat length, then the winding process is straightforward, but adapting to different motor sizes requires multiple templates
Solution Approach 1:
The receiving device incorporates dynamic parameter adjustment capabilities that allow it to produce winding heads and bars with variable dimensions. By adjusting the forming parameters, the same device can produce winding mats of different lengths and configurations, eliminating the need for multiple fixed-size templates while maintaining a straightforward winding process
Data Source
AI summary
A method and device for producing a winding mat for a stator or rotor of an electric motor, in which two conductor strands are each fed to a respective receiving device along an X direction. Oppositely disposed winding heads are formed by a shaping tool and a layer step is stamped in the winding heads in the opposite sense in a Y direction. Bars that extend in a Z direction are formed by a movement of the receiving devices on a curved path, and a lifting movement of the receiving devices is carried out. The conductor strands are transferred to a conveying device and transported in X direction by one conveying cycle. The steps are repeated until a winding mat has been produced having a defined quantity of windings formed in each instance by the two conductor strands and in each instance comprise two winding heads and four bars.