Manufacturing Dynamo-Electric Machines TRIZ Cases
- Stator Winding Laser Stripping and Welding in One Station
Laser ablation strips winding-end insulation, then laser welding joins the conductors in one station while suction removes particles.
- Steel-Reinforced Aluminum Bearing Plate for Low-Vibration E-Motor Housings
An embedded steel insert stiffens an aluminum bearing plate, cutting electric machine housing vibration without extra installation space.
- Motor Holder and Rotor Shaft Access for Drive Clutch Replacement
Radial passages in the motor holder and an orifice in the rotor shaft let a tool lock rotation for faster drive clutch replacement.
- Segment Coil Turn Geometry for Compact Stator End Cooling
A tilted bent portion opens cooling gaps between stator segment coil turns, improving heat dissipation without increasing coil end length.
- Hairpin Winding Temperature Sensor Mounting for Accurate Coil Monitoring
Attaching a temperature sensor to a hairpin bend improves thermal contact, access, and replacement while preserving winding temperature accuracy.
- Generator Air-Gap Inspection Vehicle for One-Sided Rotor Access
Remote drive groups and a focus-adjustable camera inspect long generator rotor-stator air gaps without rotor disassembly.
- Laser Welding Scan Pattern for Hairpin Pin Spatter Control
A two-pass laser scan with lower second-pass energy reduces spatter and voids while preserving deep, conductive weld nuggets in stator pin pairs.
- Elastic Winding Temperature Sensor Mount for Accurate Stator Sensing
An elastic support seats a temperature sensor in a winding recess to improve stator winding temperature accuracy and thermal contact.
- Powder-Pressed Coil-Tooth Module for Higher Motor Fill Factor
Metallic powder is compacted inside a prefabricated coil to form a tooth, improving fill factor, heat dissipation, and magnetic coupling.
- Generator Air-Gap Inspection Vehicle for Unilateral Access
Pivotable traction groups let a wireless crawler enter a generator air gap from one side and inspect rotor and stator surfaces without disassembly.
- Motor Stator Winding Separation by Controlled Heating
Controlled heating softens varnish bonding in motor stators so windings can be extracted cleanly for faster recycling with less copper-iron contamination.
- Stator Conductor Bending Sequence to Protect Insulation
Radial pre-bending of stator conductor overhangs reduces friction during circumferential bending, preserving insulation and stator quality.
- Position Sensor Alignment for Rotor Phase Angle Calibration
Iterative rotor rotation and base adjustment align a motor position sensor to correct phase angle errors and avoid repeated recalibration.
- Rotor Endwinding Spacer Block Support Without Brazed Pins
Support blocks and receptacle spacer blocks keep rotor endwinding coils aligned without brazed pins, reducing contamination and short-circuit risk.
- Stator Winding Assembly With Integrated Wire Tension Control
Integrated pulleys and load-cell feedback keep wire tension stable during spindle acceleration, improving stator winding precision.
- Armature Coil End Crank Layout for Compact Electric Rotating Machines
Inflected oblique coil sides create radial crank portions that shrink coil ends while easing manufacture and protecting lead wire insulation.
- Pressure-Welded Coil Terminals for Dissimilar Metal Connections
Cold pressure welding joins aluminum coil ends to copper or iron terminals with lower resistance, strong bonding, and simpler stator assembly.