Versatile Wire Winding Machine for Rotor and Stator Cores
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Solution Overview
Problem
Existing machines for producing wire windings on rotor or stator cores are limited in versatility, often designed for specific winding techniques and require separate machines for different configurations, increasing costs and complexity.
Innovation Solution
A machine with a modular design featuring a spindle and tailstock that can rotate and move along multiple axes, allowing for various winding configurations, including cores arranged side by side, radially, or coaxially, enabling the production of multiple types of windings on the same machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a machine is designed for a specific winding technique, then the winding precision and reliability are improved, but the versatility and adaptability deteriorate
Solution Approach 1:
The machine is designed with a universal supporting structure that can accommodate multiple winding configurations (radial, axial, mixed) through interchangeable fixtures and adjustable wire dispensing devices, allowing a single machine to perform functions previously requiring multiple specialized machines
Solution Approach 2:
The machine incorporates dynamically adjustable components including movable wire dispensing devices, rotatable cores, and adjustable fixtures that can be reconfigured during operation to switch between different winding techniques and configurations without requiring machine replacement
2Manufacturing precision
If multiple specialized machines are used for different winding configurations, then the winding precision for each configuration is maintained, but the device complexity and investment costs increase
Solution Approach 1:
Multiple winding capabilities are merged into a single integrated machine system, combining radial winding, axial winding, and mixed configuration capabilities in one platform, thereby reducing the total number of machines required while maintaining precision through specialized fixtures for each configuration
Solution Approach 2:
The machine system is segmented into modular components including interchangeable fixtures, adjustable wire dispensing devices, and independently controllable rotation mechanisms, allowing precise configuration for each winding type while simplifying maintenance and operation
3Manufacturing precision
If multiple specialized machines are used for different winding configurations, then the specific winding requirements are met, but the loss of time for setup and operation increases
Solution Approach 1:
The machine features dynamically reconfigurable components that can be adjusted during operation to switch between winding configurations, eliminating the need for complete machine changeovers and reducing setup time while maintaining configuration accuracy through programmable controls
Solution Approach 2:
Different winding configurations are pre-programmed into the machine's control system, allowing operators to quickly switch between configurations by selecting pre-configured parameters and settings, thereby reducing setup time while maintaining precision
Data Source
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AI summary
A machine for producing wire windings on rotor or stator cores, with high versatility of use, comprising: - a main supporting structure (2); - a first support (5), which is associated with the main supporting structure (2); - a spindle (8) with a horizontal axis (7), which is supported so that it can rotate about its own axis (7) by the first support (5) and can be actuated with a rotary motion about its own axis (7); - a second support (6), which is associated with the main supporting structure (2); - a tailstock (9), which is arranged opposite and coaxially with respect to the spindle (8) and is supported so that it can rotate about its own axis by the second support (6); - a third support (12), which is supported by the main supporting structure (2) and can move on command along three mutually perpendicular axes (13, 14, 15), respectively along two horizontal axes (13, 14) and along a vertical axis (15). At least one between the first support (5) and the second support (6) is movable with respect to the other along a direction that is parallel to the axis (7) of the spindle (8) and of the tailstock (9) and the third support (12) is provided with means for detachable engagement with components (62, 64, 81, 102, 136, 137) of equipment for dispensing and/or cutting wires (67, 86, 109, 139) to be wound around rotor or stator cores (53, 72, 93, 122) that can be fitted between the spindle (8) and the tailstock (9).