Winding Segment Bending Device with Segmented Locking Elements
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Solution Overview
Problem
Electrical machines require a cost-effective and space-efficient method for producing winding supports with a low overall height, as existing methods are complex and costly, and current winding segment bending techniques do not allow for optimal electrical connections while minimizing installation space.
Innovation Solution
An apparatus and method that utilize a holding device and separate main and partial bending devices, allowing for bidirectional or unidirectional rotation to bend winding segments by the same ultimate angle with different lengths, enabling efficient interleaving and electrical connection of winding segments for forming windings and establishing current phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single bending device is used to bend all winding segments, then the device structure is simple, but it cannot achieve different bending lengths for different groups of winding segments while maintaining the same bending angle
Solution Approach 1:
The bending device is divided into a main bending device and a partial bending device, each responsible for different groups of winding segments. The main bending device includes main locking elements for first group winding segments, while the partial bending device includes partial locking elements for second group winding segments. This segmentation allows each device to be optimized for specific bending requirements, achieving different bending lengths while maintaining the same bending angle through independent control of each device component.
2Reliability
If complex bending techniques are used to achieve optimal electrical connections and minimize installation space, then the electrical connection quality improves, but the production cost and process complexity increase
Solution Approach 1:
The locking elements (main locking elements and partial locking elements) are designed to pre-position and secure the winding segments before the bending action occurs. This preliminary locking ensures that the winding segments maintain their intended spatial arrangement and electrical connection geometry throughout the bending process, achieving reliable electrical connections without requiring complex post-bending adjustments or additional positioning mechanisms.
Solution Approach 2:
Different locking elements are applied to different groups of winding segments based on their specific requirements. The main locking elements engage with first group winding segments that require full bending, while partial locking elements engage with second group winding segments that require different bending characteristics. This localized approach ensures optimal electrical connections for each segment group while keeping the overall device structure manageable.
Data Source
AI summary
A device for bending a plurality of winding segments to form a winding of a winding carrier of an electric machine is provided. The device includes: a holding device designed for holding in place the winding carrier in which the winding segments are arranged; a main bending device, including a number of main locking elements, which point towards the holding device, are arranged along first sections of a circumferential line and are designed to lock exposed end sections of first winding segments; and a partial bending device, including a number of partial locking elements, which point towards the holding device, are arranged along second sections of the circumferential line and are designed to lock exposed end sections of second winding segments. The holding device on the one hand and the main bending device and the partial bending device on the other hand are rotatable relative to each other.