Bar Conductor Twisting Device for Electric Machine Stators
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Solution Overview
Problem
Existing methods for twisting bar conductors in electric machines require complex bending and welding operations, which can be cumbersome and inefficient.
Innovation Solution
A stator or rotor design and twisting apparatus that allows for automated twisting with differential pitch, simplifying the insertion and welding of bar conductors by using a twisting device with rotating bodies and locking mechanisms to align and space conductor legs uniformly within the stator core slots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional bending and welding operations are used for bar conductors, then the conductors can be assembled in stator slots, but the process becomes complex and inefficient
Solution Approach 1:
The bar conductors are pre-formed with U-shaped or P-shaped bends before insertion into the twisting device. This preliminary forming allows the conductors to be subsequently twisted and spread in a controlled manner, eliminating the need for complex bending operations after insertion and simplifying the overall manufacturing process
Solution Approach 2:
A twisting device with rotating bodies and locking mechanisms is introduced as an intermediary tool. This device holds multiple bar conductors, twists them simultaneously, and spreads their legs to the required pitch. The intermediary device automates the complex twisting and spacing operations, reducing manual manipulation and welding complexity
2Adaptability or versatility
If uniform pitch twisting is applied to all bar conductors, then the twisting process is simplified, but the ability to create varied pitch configurations is reduced
Solution Approach 1:
The twisting device is divided into multiple independent twisting units or stations, each capable of being adjusted to different pitch configurations. This segmentation allows different groups of bar conductors to be twisted with different pitches independently, providing versatility while maintaining ease of operation through modular adjustment
Solution Approach 2:
The twisting device incorporates adjustable and reconfigurable elements that allow the pitch configuration to be dynamically changed during operation. The locking mechanisms can be set to different positions, and the rotating bodies can be adjusted to create varied pitch patterns, enabling the same device to handle multiple winding configurations without manual reassembly
Data Source
AI summary
The present technology contemplates a stator or rotor of an electric machine comprising a main cylindrical body with a circular array of slots; at least one bar winding comprising a first and second plurality of basic conductors and a second plurality of special conductors. The first and second circular array comprise a first and second arc of legs of the first and second set of said conductors which are inserted as well as legs of the conductors. The present technology also contemplates electric machines and electric or hybrid drive vehicles comprising such stators of rotors.