Winding Nozzle Chamfer Geometry for Low-Stress Coil Feeding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing winding devices apply excessive bending stress to coils during winding, potentially damaging them, and enlarging the nozzle to reduce stress can lead to motor enlargement and performance deterioration.
Innovation Solution
A winding device with a nozzle featuring specific chamfered parts and a stator core with rounded corners and uniform wall thickness, ensuring the coil is wound with reduced bending stress without enlarging the nozzle or motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the nozzle size is increased to reduce bending stress on the coil, then the bending stress is reduced, but the motor size increases and motor characteristics deteriorate
Solution Approach 1:
The patent applies local quality by modifying specific regions of the nozzle geometry (chamfered parts at the nozzle hole opening) to reduce bending stress on the coil, rather than uniformly enlarging the entire nozzle. This localized geometric modification allows stress reduction without increasing overall motor size.
Solution Approach 2:
The patent changes geometric parameters of the nozzle (adding chamfered parts with specific radii) to optimize the bending stress characteristics. By adjusting parameters like the inner-diameter round chamfered part radius and outer-diameter round chamfered part radius, the patent achieves reduced coil stress without increasing nozzle size.
2Strength
If the nozzle size is increased to reduce bending stress on the coil, then the bending stress is reduced, but the slot width between teeth must be increased
Solution Approach 1:
The patent uses local quality by implementing chamfered parts at the nozzle opening rather than enlarging the entire nozzle structure. This localized modification reduces the coil bending stress without requiring increased slot width between the stator teeth.
Solution Approach 2:
The patent applies curvature by adding round chamfered parts (circular arcs) at the nozzle hole opening. These curved surfaces guide the coil more smoothly, reducing bending stress without increasing the linear dimensions of the nozzle or requiring wider slots.
3Volume of moving object
If a conventional nozzle is used, then the motor size is kept small, but the coil may be damaged due to excessive bending stress
Solution Approach 1:
The patent applies preliminary action by pre-forming chamfered parts on the nozzle before the winding process. These pre-formed geometric features prepare the nozzle to guide the coil with reduced bending stress, preventing coil damage before it occurs during the winding operation.
Solution Approach 2:
The patent uses curved surfaces (round chamfered parts) at the nozzle opening to smoothly guide the coil, replacing sharp edges that would cause stress concentration. This curvature-based design maintains compact motor size while improving coil reliability by reducing bending stress.
Data Source
AI summary
Provided is a winding device for winding a coil around a tooth. The winding device includes a nozzle that feeds out the coil. The nozzle includes a nozzle hole through which the coil is fed out, an inner-diameter round chamfered part formed on an opening edge of the nozzle hole on a side where the coil is fed out, and an outer-diameter round chamfered part formed on an outer peripheral edge at an end on the side where the coil is fed out. When a wire diameter of the coil is defined as Φc, an inner diameter of the nozzle hole is defined as Φin, a radius of curvature of the inner-diameter round chamfered part is defined as Rin, and a radius of curvature of the outer-diameter round chamfered part is defined as Rout, each of Φc, Φin, Rin, and Rout satisfies: 1.2Φc≤Φin≤1.4Φc, 0.5Φc≤Rin≤Φc, and 0.25Φc≤Rout≤0.5Φc.