Wire Twisting Assembly With Radial Pushers to Minimize Springback
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Solution Overview
Problem
The springback behavior of electrical wire shanks after deformation in twisting operations compromises the quality of alignment and coupling, leading to potential overheating and operational issues in electric machines, and reducing slot dimensions is not feasible due to complexity in insertion.
Innovation Solution
An assembly with radial pushers and shoulders is used to temporarily eliminate play between wire end portions and their seats in a ferromagnetic core, ensuring stable alignment and minimizing springback by compacting wires before twisting, while protecting insulating layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the dimensions of the slots of the ferromagnetic core are reduced to minimize springback, then the springback of the shanks is reduced, but the insertion of the shanks into the slots becomes excessively complex and may be impossible using automatic machines
Solution Approach 1:
The patent applies preliminary action by introducing pushers that temporarily eliminate play between the shanks and slots before the twisting operation. This preliminary compaction of the shanks in the slots ensures that when twisting occurs, the springback is minimized because the shanks are already tightly positioned. The pushers are removed after twisting, allowing the shanks to settle into their final positions without excessive springback, thus solving the alignment problem without requiring smaller slots.
2Manufacturing precision
If conventional devices are used to reduce play between slots and shanks, then some alignment improvement is achieved, but the springback remains significant and welding operations are considerably complicated
Solution Approach 1:
The invention applies preliminary action by using pushers to eliminate play between shanks and slots before twisting. This preliminary compaction ensures that when the twisting operation occurs, the shanks experience minimal springback, resulting in precise alignment that facilitates straightforward welding operations. The pushers are temporarily positioned, perform their function, and are then removed, leaving the shanks in optimally aligned positions for welding.
3Ease of manufacture
If the play between slots and shanks is not reduced, then insertion remains simple, but the springback after twisting compromises alignment quality and coupling stability
Solution Approach 1:
The patent applies preliminary action by introducing pushers that temporarily eliminate play between the shanks and slots before the twisting operation. This preliminary compaction of the shanks ensures that when twisting occurs, the springback is minimized because the shanks are already tightly positioned. The pushers are removed after twisting, allowing the shanks to settle into their final positions without excessive springback, thus solving the alignment problem without requiring smaller slots.
Solution Approach 2:
The pushers act as intermediary elements that temporarily fill the gap between the shanks and slots during the twisting operation. These pushers are introduced into the slots alongside the shanks, providing a mediating force that prevents excessive play and springback. After the twisting is complete, the pushers are removed, having served their purpose of ensuring precise alignment during the critical twisting phase.
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 assembly achieves optimal and stable alignment of wire ends, reducing springback and facilitating accurate welding, with improved operational stability and safety, and is cost-effective and easy to implement.
Implementation Method 1
each pusher being movable in a radial direction between a passive configuration, in which the terminal element is arranged outside the carousel, and an active configuration, in which the terminal element of each pusher enters into spaces defined between respective wire end portions
Implementation Method 2
due to the intrinsic elasticity of the fork material, the shanks of said forks feature a springback behaviour after the deformation generated by the twisting apparatus
Data Source
AI summary
An assembly for minimizing the springback of wire end portions of electrical wires that are arranged in seats of a ferromagnetic core when they are subjected to twisting, comprising a twisting apparatus which is provided with a fixed body on which a carousel is mounted so that it can rotate. The carousel comprises at least two bushings which are provided with respective channels which are substantially parallel to an axis of symmetry of the carousel, each channel defining at least one receptacle configured to partially accommodate at least one respective wire end portion of a wire that protrudes from a seat of a ferromagnetic core. The at least two bushings are configured to be made rotate in order to perform the twisting of the wire end portions of wires that protrude from the seats of the ferromagnetic core and are partially accommodated in the channels.