Electrical Winding Template Axial Displacement for Slot Fill
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Solution Overview
Problem
Existing methods for winding electrical machines, such as the flyer winding method, result in twisting of the winding wire, limiting the slot fill factor and causing coils to jam during insertion into stator slots.
Innovation Solution
The method involves axially displacing a single winding template relative to others to produce multiple winding coils without twisting or crossing, using two opposite winding heads to achieve optimal wire routing and high slot fill factor, with the ability to rotate the winding templates and use strippers for efficient coil transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If flyer winding method is used to wind electrical machines, then the winding process can be performed, but twisting of the winding wire occurs which limits the slot fill factor and causes coils to jam during insertion
Solution Approach 1:
The winding process is segmented into two distinct phases: first winding multiple coils simultaneously on separate winding templates without insertion, then transferring all templates to a transfer tool for coordinated insertion. This segmentation allows the winding operation to be completed before insertion concerns arise, eliminating twisting during the winding phase while maintaining high slot fill factor through parallel coil production.
Solution Approach 2:
The invention transitions from traditional sequential winding and insertion to a three-dimensional parallel arrangement where multiple winding templates are positioned at different axial locations simultaneously. This spatial dimensionality change enables multiple coils to be wound in parallel without interfering with each other, and allows all coils to be transferred and inserted together, eliminating the twisting problem while maximizing slot fill factor.
2Productivity
If separate individual coils are wound using flyer windings, then the winding process can be completed, but the coils jam during the process of being pulled into the slots of the stator
Solution Approach 1:
All winding templates are prepared and wound with their respective coils before any insertion operation begins. The templates are positioned axially so that all coils are ready for simultaneous transfer to the transfer tool and coordinated insertion into the stator slots. This preliminary preparation ensures that insertion occurs under controlled conditions rather than attempting to pull in coils sequentially, eliminating jamming while maintaining high productivity.
Solution Approach 2:
A transfer tool serves as an intermediary device between the winding templates and the stator slots. The templates are transferred to this intermediate carrier, which then facilitates the coordinated insertion of all coils into the stator slots. This intermediary approach allows for synchronized insertion of multiple coils, preventing the jamming that occurs with sequential pull-in methods while maintaining high production efficiency.
3Manufacturing precision
If multiple winding coils are wound one after another, then complete winding phases can be produced, but the process time increases
Solution Approach 1:
Multiple winding operations that would traditionally be performed sequentially are merged into a single parallel process. Multiple winding templates are positioned at different axial locations simultaneously, and all coils are wound in parallel using the same winding wire path. This merging of operations produces complete winding phases simultaneously rather than one after another, dramatically reducing process time while maintaining manufacturing precision through the subsequent transfer and coordinated insertion steps.
Data Source
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AI summary
A method and a device for producing an electrical winding (14) for an electrical machine (12) having the following steps: displacing a first winding template (16, 70) relative to further winding templates (16), which are disposed on at least one winding head (15), such that the first winding template (16, 17) protrudes beyond the further winding templates (16) perpendicular to the winding plane relative to an axial direction (68), winding multiple turns (48) of a winding wire (46) onto the first winding template (16, 70) through a rotational movement between a wire guide (44), which receives the winding wire (46), and the first winding template (16, 70), axially pushing back the first wound winding template (16, 70) and axially displacing a second winding template (16, 74) relative to the further winding templates (16) such that the second winding template (16, 74) protrudes beyond the further winding templates (16) in the axial direction (68) relative to the axial direction (68), winding multiple turns (48) of the winding wire (46) onto the second winding template (16, 74) through a rotational movement between the wire guide (44), which receives the winding wire (46), and the second winding template (16, 74), disposing a translation tool (20) axially opposite to the winding templates (16) and stripping the turns (48) wound on the winding templates (16) onto the translation tool (20), collecting the turns (48) in the axial direction (68) in grooves (62) of a rotor or stator (60) of the electrical machine (12).