Winding Method for Non-Circular Electric Coils
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge is to achieve contour-conforming winding of strand-shaped materials onto non-circular carrier bodies, particularly minimizing bulging and maximizing space utilization in limited accessible areas, such as the pole teeth of electric motors, where existing methods face limitations due to material properties and geometry constraints.
Innovation Solution
Applying a defined transverse force to the winding material between the point of engagement and the outlet point from the feeding device, which applies elastic pre-stress and deflects the material to form angled sections, compensating for bulging and ensuring tight engagement with the carrier body, using a preforming element in conjunction with the feeding device to apply this force cyclically and adapt to the carrier body's contour.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a round wire is used for winding onto a non-circular carrier body, then the winding process is simpler, but bulging occurs between corner points causing loss of winding space
Solution Approach 1:
The patent applies a transverse force to the winding material in advance, between the point of engagement and the outlet point, to pre-counteract the bulging that would occur during winding. This preliminary anti-action prevents the wire from springing back and forming bulges, ensuring continuous tangential engagement with the carrier body surface.
Solution Approach 2:
The winding material is pre-stressed with a transverse force before it reaches the carrier body, creating a pre-formed shape that anticipates the required contour-conforming engagement. This preliminary action prepares the material to fit the non-circular cross-section without bulging.
2Manufacturing precision
If tension force is increased to prevent bulging, then contour-conforming engagement improves, but material damage or deformation increases
Solution Approach 1:
Instead of applying uniform tension force throughout the winding material, the patent applies a localized transverse force only in the specific area between the point of engagement and the outlet point. This local quality approach prevents bulging where needed while avoiding excessive stress and potential damage to the rest of the material.
3Quantity of substance
If the carrier body has a non-circular cross-section to maximize space utilization, then winding space utilization improves, but the winding process becomes more complex
Solution Approach 1:
The patent modifies the physical parameters of the winding material by applying a transverse force that changes its shape and stress state. This parameter change allows the material to conform to non-circular cross-sections, enabling maximum space utilization in pole teeth while maintaining a relatively simple winding 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
This method effectively minimizes bulging and achieves contour-conforming lay-ups, optimizing the use of available space by maintaining a consistent engagement with the carrier body, even in areas with complex geometries, thereby enhancing the packing density and efficiency of winding.
Implementation Method 1
the material opposes a change of shape induced by the bending operation during winding by plastic or elastic reactions
Data Source
AI summary
A winding method for producing, for example, electric coils, wherein strand-shaped winding material (8) fed by means of a feeding device (7) is wound onto a carrier body having a non-circular cross-section by means of moving the winding material (8) and the carrier body relative to each other. Prior to placing the winding material (8) onto the surface to be wound, a force is applied onto the material transversely to the longitudinal extension thereof such that the strand-shaped winding material conform to the shape of the surface of the carrier body having a non-circular cross-section.