Wire Forming Apparatus Rack Dynamics for Segment Removal
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Solution Overview
Problem
Existing wire forming apparatuses for dynamoelectric machines are inefficient in removing formed wire segments due to complex component structures and limited movement capabilities, leading to machine downtime and increased construction costs.
Innovation Solution
A wire forming apparatus with a rack and interleafed forming structures that move in distinct directions, utilizing scissor gates and pneumatic cylinders to form and easily release wire segments, reducing the number of components and enhancing operational reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple forming structures are mounted on a fixed apparatus with limited movement capability, then wire segments can be formed, but removal of formed wire segments becomes difficult and time-consuming
Solution Approach 1:
The forming structures are mounted on a movable rack that can translate along the wire length direction. After forming multiple wire segments simultaneously, the rack moves to release the formed segments, enabling easy removal while maintaining high formation speed
Solution Approach 2:
The apparatus divides forming structures into multiple independent units mounted on the rack, each capable of forming wire segments simultaneously. The rack itself is segmented to allow independent movement for release operations
2Adaptability or versatility
If numerous components with multiple parts are used in the wire forming apparatus, then complex forming operations can be performed, but machine reliability decreases due to potential component failures
Solution Approach 1:
Multiple forming structures are combined on a single movable rack, sharing common support and movement mechanisms. This reduces the total number of independent components compared to having separate forming stations, thereby improving reliability while maintaining versatility
Solution Approach 2:
The rack serves multiple functions: it supports multiple forming structures, provides a common movement mechanism for releasing all segments simultaneously, and acts as a unified release platform. This multi-functionality reduces the need for separate components for each function
3Ease of manufacture
If forming structures are arranged in a fixed configuration with limited movement, then apparatus construction can be simplified, but wire segment removal requires machine downtime
Solution Approach 1:
The rack is designed with simple linear movement capability along the wire length, adding minimal structural complexity while enabling rapid release of formed segments without requiring machine shutdown
Data Source
AI summary
A wire forming apparatus comprises a first rack moveable relative to a second rack in a first direction, a plurality of first forming structures provided on the first rack, and a plurality of second forming structures provided on the second rack. Each of the plurality of first forming structures is configured to move in the first direction, is separated from an adjacent first forming structure, and is configured to move in a second direction closer to the adjacent first forming structure when the first rack moves relative to the second rack. Each of the plurality of second forming structures is configured to move in the first direction, is separated from an adjacent second forming structure, and is configured to move in the second direction closer to the adjacent second forming structure when the first rack moves relative to the second rack. The second direction is different from the first direction.