Annular Stator Assembly with Linear-to-Circular Pole Positioning
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Solution Overview
Problem
Existing methods for assembling annular stators of dynamo-electric machines face challenges in ensuring accurate positioning of pole members and connection leads, leading to complications such as excessive bending and positioning difficulties, which affect the assembly and functionality of the stator.
Innovation Solution
A method involving a train of pole members moved along a rectilinear trajectory, with specific displacement devices to transition them to a circular trajectory, allowing rotation around a center to orient winding axes radially, and a device to change the spatial orientation of the last pole member to close the train, ensuring accurate positioning and minimizing connection lead lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pole members are pushed through a curvilinear slot to form an annular configuration, then the assembly can be formed, but the positioning accuracy of pole members deteriorates due to engagement complications with slot sides
Solution Approach 1:
The assembly process is segmented into two distinct phases: first, pole members are assembled linearly on a rectilinear trajectory where precise positioning is achieved; second, the already-positioned poles are transferred to and formed into the annular configuration. This segmentation allows each phase to optimize for its specific requirement - positioning accuracy during linear assembly, and geometric formation during annular transformation.
Solution Approach 2:
The pole members are preliminarily assembled and positioned with high precision on a rectilinear trajectory before being transformed into the annular configuration. This preliminary linear assembly ensures accurate positioning of connection leads and pole members, which would be difficult to achieve if positioning were attempted during the annular formation process itself.
2Reliability
If connection leads are present between poles during assembly, then electrical connections are established, but the assembly operation becomes complicated requiring transfer of assembled pole members with connection leads
Solution Approach 1:
The assembly process separates the mechanical assembly of pole members from the electrical connection establishment. Pole members are first assembled mechanically on the rectilinear trajectory without connection leads, achieving precise positioning. Connection leads are then added in a subsequent step after the annular configuration is formed, simplifying the primary assembly operation while ensuring reliable electrical connections.
Solution Approach 2:
The mechanical assembly and positioning of pole members is performed preliminarily before adding connection leads. This preliminary assembly on the rectilinear trajectory establishes the precise geometric configuration, and connection leads are added afterward, avoiding the complexity of maneuvering and positioning both poles and flexible connection leads simultaneously.
3Reliability
If pole members are assembled with connection leads present, then electrical scheme is formed, but accurate final positioning of pole members and connection leads deteriorates
Solution Approach 1:
The process segments mechanical positioning and electrical connection into separate operations. Pole members are positioned with high precision during linear assembly, and connection leads are added in a subsequent step after annular formation, ensuring that the rigid pole members achieve accurate positioning without the complicating factor of flexible connection leads interfering with the positioning process.
Solution Approach 2:
The precise positioning of pole members is performed preliminarily during linear assembly before connection leads are added. This ensures that the rigid structural elements are accurately positioned first, and the flexible connection leads are subsequently routed and connected, maintaining high positioning accuracy for the pole members while establishing the electrical scheme.
4Reliability
If connection leads are allowed to connect coils, then electrical scheme is achieved, but excessive bending and positioning difficulties occur
Solution Approach 1:
The annular configuration is preliminarily formed with pole members positioned on the rectilinear trajectory before connection leads are added and manipulated. This preliminary formation establishes the correct geometric arrangement and minimizes the required length of connection leads, reducing bending and positioning difficulties when the leads are subsequently routed and connected.
Data Source
AI summary
Embodiments of the present disclosure may include producing a stator of a dynamo-electric machine. The method may include moving along a predetermined rectilinear trajectory a train of pole members arranged according to a predetermined starting spatial orientation. At a predetermined passage position, a first pole member and one or more intermediate pole members may pass from the rectilinear trajectory to a circular trajectory having a centre. In some embodiments, the method may include positioning a last pole member of the train along the circular trajectory adjacent to the first pole member and to the last intermediate pole member changing, at a change position its spatial orientation from the predetermined starting spatial orientation to a final spatial orientation in which it is radially oriented with respect to the centre of the circular trajectory.