Rotary Electric Machine Bobbin Positioning for Damage-Free Assembly
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Solution Overview
Problem
The positioning of bobbins in rotary electric machines is prone to misalignment, leading to decreased workability and reliability due to potential damage and increased assembly complexity, particularly when using segment coils.
Innovation Solution
The use of protrusions on the stator core projections and flanges on the bobbin ends, which engage in a radial and axial direction to securely fix the bobbin position, ensuring accurate alignment and reducing the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the projection of the bobbin is fitted into the concave portion at a large angle, then the positioning capability is improved, but the force required for press-fitting increases and the risk of damage to the bobbin increases
Solution Approach 1:
The invention changes the fitting angle parameter from a large angle to substantially 0 degrees (perpendicular approach), reducing the press-fitting force and risk of damage while maintaining positioning accuracy through the engagement geometry of the projection and recess
2Manufacturing precision
If the projection is fitted at an angled position, then positioning is achieved, but damage to the projection may occur and it becomes difficult to check the location after assembly
Solution Approach 1:
The invention performs preliminary visual inspection of the projection before assembly to detect any pre-existing damage, and the perpendicular fitting approach prevents additional damage during assembly, making it easier to identify damaged components before they are installed
3Device complexity
If the bobbin is positioned without proper alignment features, then the assembly process is simpler, but the bobbin may move in radial or axial direction and be misaligned
Solution Approach 1:
The projection and recess engagement structure provides self-positioning and self-alignment of the bobbin during assembly, automatically ensuring correct radial and axial positioning without requiring complex external alignment fixtures or procedures
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
A stator includes a stator iron core including a plurality of slots, and bobbins fitted into the slots. Each of the bobbins includes flanges provided at both respective ends of the stator in an axial direction, and protrusions provided on the respective flanges. The stator iron core includes projections protruding from inner surfaces of the slots. The bobbins are positioned by engaging the protrusions and the projections to each other.