Electric Wire Shaping Dies with Variable Gap for Stator Coil Width Control
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Solution Overview
Problem
Existing methods for shaping electric wires for stator coils in electric rotating machines face challenges due to insulation expansion and contraction, leading to uneven widths and potential electric discharge, as well as difficulties in maintaining desired dimensions and insulation performance.
Innovation Solution
An electric wire shaping apparatus with a pair of male and female shaping dies and a pressing mechanism, where the gap between bent parts is different from that between straight parts, allowing for consistent width across the turn portion, and a suppressing mechanism to prevent bulging, ensuring the desired finished width and insulation integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a constant gap between shaping dies is used for the entire turn portion, then the manufacturing process is simple, but the insulator expands and contracts unevenly during bending, causing width variation and potential electric discharge
Solution Approach 1:
The patent applies local quality by making the gap between shaping dies non-uniform along the turn portion. Specifically, the gap is smaller at bent parts and larger at straight parts, allowing the insulator to be compressed appropriately at each location during the shaping process. This local variation in gap size compensates for the insulator's expansion and contraction during bending, ensuring consistent width throughout the turn portion while maintaining manufacturing simplicity.
2Strength
If the insulator is made hard by crystallization, then it maintains structural integrity, but it is difficult to shape the turn portion to the desired dimension due to resistance to deformation
Solution Approach 1:
The patent applies parameter changes by controlling the crystallization degree of the insulator to adjust its hardness and deformability. By optimizing the crystallization parameters, the insulator achieves a balance between maintaining structural integrity and allowing sufficient deformation during the shaping process to reach the desired turn portion dimensions.
3Ease of manufacture
If the insulator is made soft by preventing crystallization, then it is easy to shape, but it returns to its initial shape after shaping, making it difficult to achieve the desired finished dimension
Solution Approach 1:
The patent applies parameter changes by controlling the crystallization degree of the insulator to achieve optimal deformability during shaping. By adjusting crystallization parameters, the insulator becomes sufficiently soft to allow easy shaping while retaining enough structural memory to maintain the desired finished dimension after the shaping process, preventing excessive springback.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus effectively shapes the electric wire to maintain consistent width and prevent bulging, enhancing the insulation performance and reducing the risk of electric discharge, while allowing for cost-effective manufacturing of the shaping dies.
Implementation Method 1
pressing the turn portion of the electric wire between the shaping surfaces of the male and female shaping dies
Implementation Method 2
the insulator is expanded in the length-wise direction and thinned in the width-wise direction of the turn portion
Data Source
AI summary
An electric wire shaping apparatus includes a pair of male and female shaping dies and a pressing mechanism. Each of the male and female shaping dies has a shaping surface that includes a plurality of straight parts and a plurality of bent parts. The pressing mechanism moves one of the male and female shaping dies toward the other, thereby pressing a turn portion of an electric wire between the shaping surfaces of the male and female shaping dies in a width-wise direction of the turn portion. Furthermore, the male and female shaping dies are so configured that when they are located closest to each other, a gap W2 between a corresponding pair of the bent parts of the shaping surfaces of the male and female shaping dies is different in size from a gap W1 between a corresponding pair of the straight parts of the shaping surfaces.