Wire Contour Bending Unit for Electric Machine Coil Winding
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Solution Overview
Problem
Existing methods for producing coil windings in electrical machines are inefficient due to intermittent processes and lack of continuous control over wire shaping, leading to suboptimal production times and reduced productivity.
Innovation Solution
A method and device that utilize a bending unit with shaped elements capable of displacement along a process section, incorporating a feed movement and bending movement to continuously shape wire sections into desired contours, allowing for continuous production and optimized process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a bending unit with movable forming elements is used to shape wire sections, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The forming elements are designed to be movable relative to each other along the process path, allowing dynamic adjustment of the bending geometry. This enables precise control of wire contour formation while maintaining flexibility in the device design, resolving the contradiction between precision and complexity.
2Productivity
If the bending unit is moved continuously along the process path during bending operation, then productivity is improved, but control difficulty increases
Solution Approach 1:
The bending unit is moved continuously along the process path during the bending operation, eliminating idle time between operations. The forming elements perform bending actions continuously as the unit moves, ensuring uninterrupted production flow and maximizing productivity while maintaining manageable control through synchronized movement.
3Productivity
If loading and unloading areas are separated along the process path, then productivity is improved, but process complexity increases
Solution Approach 1:
The process path is segmented into distinct functional areas including a loading area and a separated unloading area. This spatial segmentation allows independent optimization of each operation, enabling continuous loading while unloading occurs elsewhere in the system, thereby improving productivity without creating excessive complexity through modular design.
Data Source
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AI summary
The invention relates to a method for producing a wire contour for a coil element of a coil winding of an electric machine, comprising: providing a bending unit (6) with forming elements (12) that is movable along a process path (4); receiving and clamping a wire section (9) in the bending unit (6) in a receiving area (8) along the process path (4); performing a bending process in which the wire section (9) is formed into a wire contour for a coil element of a coil winding of an electric machine by means of the forming elements (12) of the bending unit (6); and releasing the wire contour from the bending unit (6) in a discharge area (14) that is arranged along the process path (4) at a distance from the receiving area (8).The bending process further comprises the following: moving the bending unit (6) with the forming elements (12) by means of a feed movement between the receiving area (8) and the discharge area (14), and moving the forming elements (12) relative to each other by means of a bending movement in order to form the wire section (9) received in the bending unit (6) into the wire contour. Furthermore, a device for producing a wire contour for a coil element of a coil winding of an electrical machine is provided (Fig. 2).