Wire-End Bending Apparatus with Radial Tool Arrangement
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Solution Overview
Problem
Existing wire end bending devices for electrical machine components require a high space requirement and are cost-intensive due to complex manufacturing processes, and existing methods are not efficient in producing high-quality components with a compact structure.
Innovation Solution
A wire end bending device with a compact design that uses axial and radial bearings to absorb process forces, allowing for a large number of setting tools to be used in a small space, and a method that involves receiving and rotating devices to bend wire ends in a circumferential direction, with drive elements and bearings supporting the tools to maintain stability and facilitate quick assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple setting tools are used to bend wire ends simultaneously, then productivity and quality are improved, but the vertical space requirement and device complexity increase
Solution Approach 1:
The patent transitions from a vertical stacking arrangement of setting tools to a horizontal radial arrangement around a central axis. Multiple setting tools (first, second, third, and fourth setting tools) are positioned at different radial locations rather than stacked vertically, enabling simultaneous wire end bending while reducing vertical space requirements.
Solution Approach 2:
The device is divided into multiple independent setting tools that can be individually positioned and operated. Each setting tool handles specific wire ends at different radial locations, allowing parallel processing of multiple wire ends simultaneously while maintaining a compact overall structure.
2Reliability
If setting tools are designed with thicker walls for structural strength, then reliability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The setting tools are merged into a coordinated system rotating around a common central axis, sharing common structural support and drive mechanisms. This allows for thinner-walled, simpler individual tool designs while maintaining overall structural integrity through the integrated system architecture.
Solution Approach 2:
The setting tools are designed as universal components that can be positioned at different radial locations and oriented to handle different wire ends. This standardized, multi-position design simplifies manufacturing compared to custom-designed thick-walled tools for each specific location.
3Productivity
If all wire ends are bent simultaneously using multiple setting tools, then productivity is improved, but the space requirement and manufacturing cost increase
Solution Approach 1:
The patent arranges setting tools in a horizontal plane around a central axis rather than stacking them vertically, enabling simultaneous processing of multiple wire ends while maintaining a compact footprint and reducing manufacturing complexity associated with vertical stacking mechanisms.
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The invention relates to a wire-end bending apparatus (10) for bending wire ends when producing an electrical machine component provided with coils, by means of which apparatus wire ends protruding out of an annular housing (11) of the component are bent in a circumferential direction. A receiving device and twisting device (12a, 12b, 12c, etc.) are used to receive and twist the wire ends for the purpose of bending in the circumferential direction (U). The wire ends to be received in the various receiving devices and twisting devices (12a, 12b, 12c, etc.) are arranged so as to be radially offset from one another. Thrust bearings (16) are used to absorb axial forces acting on the receiving devices and twisting devices (12a, 12b, 12c, etc.) such that the devices are rotatable about a common axis (A) relative to one another and to the housing (11) but are kept stationary relative to one another in the axial direction. Radial bearings (15a, 15b, 15c, 15d) are distributed around the receiving devices and twisting devices (12a, 12b) and are used to absorb radial forces.