Wire-End Straightening Clamp for Damage-Free Motor Coil Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for straightening protruding wire ends of enamelled copper wires in coil arrangements, such as those in small electric motors, often require additional components and risk damaging the wire ends, especially when using pliers or similar tools.
Innovation Solution
A clamping device holds the wire ends at a distance from their free ends, and a straightening device, designed in two levels with actuators and prism-shaped elements, gently straightens the wire ends without additional components, ensuring precise alignment for insertion into injection molding tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a bell-shaped component is manually slid over the wire ends to straighten them, then the wire ends are held in the intended position, but an additional part must be manufactured and a separate assembly step is required
Solution Approach 1:
The clamping device integrates both the clamping function and straightening function into a single component. The clamping elements can clamp the wire ends while the straightening elements simultaneously straighten them, eliminating the need for separate bell-shaped components and reducing assembly steps.
Solution Approach 2:
The clamping device is designed to perform multiple functions: clamping the wire ends, straightening the protruding portions, and positioning the wire ends for injection molding. This multi-functional design replaces the single-function bell-shaped component.
2Shape
If pliers are used to straighten the wire ends, then the wire ends can be shaped, but the enamel coating on enameled copper wires is damaged
Solution Approach 1:
The straightening elements are designed with specific local qualities - they have rounded edges and surfaces that contact only the protruding uninsulated portions of the wire ends. This localized straightening approach avoids contact with and damage to the enamel coating on the main body of the wire ends.
Solution Approach 2:
The straightening elements apply force only to the protruding portions of the wire ends that extend beyond the clamping device, rather than gripping the entire wire end. This partial action straightens the necessary portions without damaging the enamel coating.
3Ease of operation
If wire ends are clamped close to their free ends for straightening, then the wire ends can be held securely, but the wire ends are at risk of damage
Solution Approach 1:
The clamping device divides the wire end into two zones: the clamped portion (held securely by clamping elements) and the free protruding portion (to be straightened). This segmentation allows secure clamping at one location while leaving the protruding portions accessible for damage-free straightening.
4Manufacturing precision
If multiple wire ends are processed sequentially, then each wire end can be straightened carefully, but the processing time increases
Solution Approach 1:
The clamping device is designed with multiple clamping elements and straightening elements that can simultaneously process multiple wire ends. This parallel processing capability maintains high straightening quality while significantly reducing total processing time compared to sequential processing.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an apparatus (1) for straightening wire ends (3) of enamelled copper wires of electric motors, the apparatus having a clamping apparatus (6) for clamping the wire ends (3) and a straightening apparatus (7) for straightening the wire ends (3) protruding beyond the clamping apparatus (6). The clamping apparatus (6) and the straightening apparatus (7) each have two actuators (8-11), by means of which clamping elements (12, 13) and straightening elements (14, 15) can be moved transversely with respect to the axis of the wire ends (3).