Bar Winding Group Assembly for Variable Hairpin Alignment
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Solution Overview
Problem
Existing assembly methods for bar windings in electric machines are limited in their ability to handle conductors with non-circular cross-sections and varying leg lengths, requiring additional gripper assemblies for insertion into stator or rotor cores, and are not adaptable for assembling windings with different hairpin spans or pitches.
Innovation Solution
An assembly apparatus featuring an annular fixture with slots and a conductor insertion device that allows for the precise alignment and insertion of bar conductors with varying leg lengths and cross-sections, using a guiding device to manage the legs and a moving device to rotate them into position, eliminating the need for additional gripper assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional assembly methods are used for bar windings, then round wire conductors can be assembled, but conductors with non-circular cross-sections (rectangular, trapezoidal) cannot be properly handled
Solution Approach 1:
The assembly apparatus is designed with a universal fixture system that can accommodate multiple conductor types (round wire, rectangular, trapezoidal) through adjustable clamping mechanisms and interchangeable insertion tools, allowing a single device to perform multiple conductor assembly functions without requiring separate specialized equipment for each conductor geometry
2Adaptability or versatility
If additional gripper assemblies are used to insert conductors into stator or rotor cores, then conductors with varying leg lengths can be handled, but the assembly process becomes more complex
Solution Approach 1:
The apparatus combines the gripping function and the insertion function into a single integrated mechanism. The fixture system incorporates adjustable clamps that can grip conductors of different leg lengths, and the insertion device is designed to work with these clamps to push conductors into the core, eliminating the need for separate gripper assemblies for each conductor variation
3Manufacturing precision
If conventional fixtures are used, then assembly can proceed, but alignment precision for conductors with different hairpin spans and pitches cannot be achieved
Solution Approach 1:
The fixture system incorporates adjustable and reconfigurable elements that can be dynamically positioned to match different hairpin spans and pitches. The fixture includes movable guides and adjustable spacing mechanisms that can be reconfigured for each conductor type, allowing precise alignment without requiring completely different fixtures for each span variation
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
An assembly for assembling at least one winding group of a bar winding for an electric machine, said winding group (2) comprising a plurality of bar conductors (4), each bar conductor (4) of said plurality of bar conductors (4) comprising a first leg (6), a second leg (8) and a bridge portion (10) connecting said first leg (6) and said second leg (8) to each other, each of said bar conductors being shaped so that the respective legs (6, 8) are mutually spread by a predetermined distance; - said assembly comprises an annular fixture (12) delimiting a plurality of slots, each slot (16) being adapted to receive at least one portion of either said first leg (6) or said second leg (8), said assembly comprises at least one guiding device (28) which defines an annular containment housing (30), adapted to receive at least partially the legs (6, 8) of said plurality of legs (6,8) of said plurality of bar conductors (4) when they are housed in said plurality of slots (16, 16', 16"), forming at least one radial containment wall (39, 40) for said legs (6, 8).