Wire Lead Termination in Dynamo Electric Machine Cores
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Solution Overview
Problem
The increasing complexity and time required for terminating leads of wire coils in dynamo-electric machine components, such as stators, due to the growing number and size of wires, makes existing manual and automatic processes inefficient and difficult to automate, especially in achieving compact designs without additional supporting components.
Innovation Solution
The use of temporary termination members on magnetic cores to guide and twist wire leads into predetermined configurations, with a wire manipulator that bends and twists the wires to form helical sections matching the coil turns, and the use of restraining members to prevent coil movement during twisting, allowing for automatic and compact lead termination without additional support components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual operations are used for preparing and cutting leads, then flexibility and adaptability are maintained, but production time increases and automation becomes difficult to achieve
Solution Approach 1:
A winding tool with integrated slots serves as an intermediary device that automatically prepares, positions, and cuts multiple leads simultaneously. The tool includes a manipulating device that grasps leads and moves them to predetermined positions, and a cutting device that cuts leads at precise locations, enabling automated lead termination without manual intervention
Solution Approach 2:
The winding tool is divided into functional segments: lead preparation slots, manipulating devices for individual lead control, cutting devices for precise truncation, and twisting devices for lead assembly. This segmentation allows each component to perform its specific function efficiently in an automated sequence
2Stability of the object's composition
If additional supporting components are used for lead routing, then lead stability is improved, but device complexity and compactness are worsened
Solution Approach 1:
The winding tool itself provides the support and positioning functions through its integrated slots and manipulating devices, eliminating the need for separate support components. The tool's structure serves multiple functions: guiding leads during winding, positioning them for cutting, and maintaining stability during the termination process
Solution Approach 2:
The winding tool is designed as a multi-functional device that combines lead preparation, positioning, cutting, and twisting operations in a single integrated system. The slots and manipulating devices serve multiple purposes throughout the lead termination process, reducing overall device complexity
3Volume of moving object
If leads are routed directly in contact with coils, then compactness is achieved, but risk of coil damage increases
Solution Approach 1:
The winding tool performs preliminary positioning and preparation of leads in controlled slots before they are routed near the coils. Leads are pre-formed and positioned with precise control, allowing them to be routed compactly near coils without direct contact that could cause damage
Solution Approach 2:
The winding tool acts as an intermediary that precisely controls lead positioning and routing. The tool's manipulating devices and cutting devices ensure leads are properly prepared and positioned before final placement, preventing direct harmful contact with coils while achieving compact routing
4Quantity of substance
If the number of wires per lead is increased, then electrical capacity is improved, but termination process complexity and time increase
Solution Approach 1:
The winding tool combines multiple leads with multiple wires each into a single integrated preparation and cutting operation. The manipulating device grasps and positions multiple wires simultaneously, and the cutting device truncates all leads at once, maintaining productivity despite increased wire quantity
Solution Approach 2:
The tool segments the handling of multiple wires within each lead, providing individual control through manipulating devices while performing collective operations like simultaneous cutting and twisting. This segmentation allows efficient processing of high wire counts without proportionally increasing process complexity
Data Source
AI summary
Method and Apparatus are provided for automatically disposing plural wires along predetermined trajectories, wherein the plural wires extend from coils wound in slots of dynamoelectric machine cores. Plural wires forming leads are located in predetermined positions and caused to extend along predetermined directions by means of manipulating equipment and tooling which operates automatically. In addition, the equipment and tooling cause the plural wires to become twisted and cut to form portions for connection to terminals. The tooling is provided with reference surfaces and seats which are used to bend the plural wires along the predetermined trajectories and to provide a position constraint for the portions becoming twisted. Apparatus can be provided for positioning portions of a plurality of restraining members in the spacing existing between the bridges of the coils and the end faces of a dynamo electric machine core.