Coil Winding Nozzle Reorientation in Compact Motor Cores
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Solution Overview
Problem
Existing winding and termination solutions for dynamoelectric machines face challenges in efficiently orienting and moving conductor dispensing nozzles within compact core structures, particularly for complex and low-voltage applications, where large conductors require significant pulling tension and precise, variable trajectories, often resulting in mechanical resistance and wear issues.
Innovation Solution
A compact mechanism that allows the conductor dispensing nozzle to rotate and translate within a coaxial configuration of a drive tube and support shaft, enabling precise and rapid movements while maintaining mechanical resistance and adaptability to different core configurations, using a combination of gears, motors, and support structures to optimize inertia and reduce wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a traditional rotation mechanism is used to re-orient the needle between winding and termination stages, then the needle can be positioned correctly for different operations, but the mechanism occupies excessive space within compact core structures
Solution Approach 1:
The needle rotation mechanism is nested within the drive tube assembly, where the needle rotates on its own axis while being carried by the drive tube. This nested configuration allows the rotation function to be integrated into the existing structure without requiring additional external space, thereby resolving the contradiction between operational capability and space occupation.
Solution Approach 2:
Instead of rotating the entire needle assembly in a plane parallel to the core's longitudinal axis (traditional approach), the invention enables the needle to rotate on its own axis (dimensional change). This allows the needle passage to be re-oriented from perpendicular to parallel with the longitudinal axis while occupying minimal space within the compact core structure.
2Manufacturing precision
If the needle is moved rapidly and precisely for complex trajectories, then termination leads can be placed accurately, but mechanical resistance and wear increase
Solution Approach 1:
The invention replaces complex mechanical positioning mechanisms with a more streamlined system where the needle rotates on its axis while being carried by the drive tube. This substitution reduces the number of mechanical contact points and moving parts, thereby reducing friction, wear, and mechanical resistance while maintaining precise trajectory control through coordinated rotation and translation motions.
3Quantity of substance
If large section conductors are used for low voltage applications, then current carrying capacity is improved, but pulling tension on the dispensing nozzle increases causing mechanical resistance
Solution Approach 1:
The invention employs dynamic motion control where the needle rotates on its axis while being carried by the drive tube in coordinated motions. This dynamic approach allows the conductor to be fed through the needle passage with reduced friction and resistance, enabling the handling of large section conductors with high current carrying capacity without excessive pulling tension that would compromise mechanical reliability.
Data Source
Figure 1A~1B
Figure 2
Figure 2A~7
AI summary
Apparatus and method for winding coils C of at least one electrical conductor W for at least one core (11) of a dynamoelectric machine and for forming termination leads (100) of the coils, the core having a longitudinal axis (11'), comprising: a dispensing member (20) for dispensing the electrical conductor, the dispensing member having a portion of conductor passage (21) and an exit (20') from where the conductor reaches the core; relatively moving the dispensing member (20) with respect to the core during winding or forming of the termination leads; supporting the dispensing member (11); reorienting the exit (20') between a first orientation (103) wherein the exit is positioned internally of the core and faces in a direction (102) away from the centre of the core and a second orientation (104) for terminating the core wherein the exit faces in a direction (102') towards the centre of the core.