Adjustable Coil Aligning Apparatus for Variable Stator Diameters
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Solution Overview
Problem
Existing aligning apparatuses for forming aligned coils are limited in versatility, requiring multiple machines to produce coils of different diameters for various stators, leading to increased manufacturing costs and inefficiency.
Innovation Solution
An aligning apparatus with an outer jig and an inner jig, where the inner jig's hole-forming members are rotatable and radially movable, allowing the formation of aligned coils of various diameters by adjusting the radial position of the hole-forming members to match the coil segments' positions, enabling the use of a single machine to produce coils for different stator dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple dedicated machines are used to produce coils of different diameters, then manufacturing precision for various stator dimensions is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The aligning apparatus is designed with adjustable hole-forming members on the inner jig that can be positioned at different radial locations, allowing a single machine to form aligned coils of various diameters. The partitioning members on the outer jig and hole-forming members on the inner jig work together to guide and align coil segments, while the adjustability of the hole-forming members enables the same apparatus to accommodate different stator dimensions without sacrificing alignment precision.
Solution Approach 2:
The inner jig is designed with hole-forming members that can be radially moved to different positions, transforming the apparatus from a static, fixed-diameter configuration to a dynamic, adjustable configuration. This dynamic capability allows the aligning apparatus to adapt to different coil diameter requirements while maintaining the precision needed for proper coil segment alignment.
2Adaptability or versatility
If multiple dedicated machines are used for different coil diameters, then adaptability to various stator dimensions is improved, but manufacturing cost increases
Solution Approach 1:
A single aligning apparatus is designed to perform multiple functions by adjusting the radial position of hole-forming members on the inner jig. This universal design eliminates the need for multiple dedicated machines for different coil diameters, thereby reducing manufacturing costs while maintaining full adaptability to various stator dimensions. The apparatus can produce aligned coils ranging from small to large diameters using the same equipment.
3Ease of manufacture
If a single machine is used to produce coils of various diameters, then manufacturing cost is reduced, but manufacturing precision may deteriorate
Solution Approach 1:
The adjustable hole-forming members on the inner jig enable the single machine to dynamically adapt to different coil diameter requirements while maintaining precise alignment. The radial adjustability allows the hole-forming members to be positioned exactly where needed for each specific coil diameter, ensuring that coil segments are properly aligned regardless of the target diameter, thus preserving manufacturing precision.
Solution Approach 2:
The apparatus controls the alignment precision by adjusting the radial position parameter of the hole-forming members. By changing this parameter according to the required coil diameter, the system maintains optimal alignment precision across different production scenarios while using a single versatile machine, thereby avoiding the need for multiple dedicated machines.
4Adaptability or versatility
If multiple dedicated machines are used, then versatility for different stator dimensions is improved, but productivity is reduced due to increased setup and maintenance requirements
Solution Approach 1:
The aligning apparatus serves as a universal machine that can produce aligned coils for various stator dimensions within a single production line. By eliminating the need for multiple dedicated machines, the system reduces setup time between different production runs and minimizes maintenance requirements, thereby improving overall manufacturing efficiency and productivity while maintaining full versatility.
Data Source
AI summary
An aligning apparatus is provided for aligning coil segments in an annular shape to form an aligned coil. Each of the coil segments has a pair of first and second leg portions. The aligning apparatus includes an outer jig and an inner jig. The outer jig has partitioning members arranged in a radial fashion. The partitioning members are spaced at such intervals as to allow each of the first leg portions of the coil segments to be inserted between one circumferentially-adjacent pair of the partitioning members. The inner jig has hole-forming members arranged radially inside the partitioning members of the outer jig. Each of the hole-forming members has formed therein a hole in which one of the second leg portions of the coil segments is to be inserted. Moreover, the hole-forming members are configured to be rotatable relative to the outer jig in a circumferential direction and radially movable.