Coil Insertion Guide Device with Segmented Grooves
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Solution Overview
Problem
Conventional coil insertion methods often result in damage to guide jigs and insulating members due to overloading and interference between the coil and insulating members during insertion into stator slots.
Innovation Solution
A coil insertion guide device featuring a positioning jig with cuff guides that include a cuff support groove and a coil guide groove, which supports and positions insulating members and guides the coil insertion to prevent biting and apply axial tension, reducing damage and ensuring smooth insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a guide jig is used to guide the movement of the coil and insulating member, then the coil insertion is facilitated, but the guide jig is easily overloaded and damaged
Solution Approach 1:
The guide member is divided into two distinct functional grooves: a cuff support groove for supporting the insulating member and a coil guide groove for guiding the coil. This segmentation allows each groove to be optimized for its specific function, preventing overload and damage to the entire guide structure.
Solution Approach 2:
The cuff support groove acts as an intermediary element that supports the insulating member (cuff) during coil insertion. By providing this intermediate support structure, the coil can be guided into the slot without directly contacting and potentially damaging the insulating member, thereby protecting both the insulating member and the guide structure.
2Ease of manufacture
If an insulating member is inserted into a slot beforehand, then the slot is prepared for coil insertion, but the insulating member may be damaged because a coil bites the insulating member during insertion
Solution Approach 1:
The cuff support groove serves as an intermediary support structure that holds the insulating member (cuff) in place during coil insertion. This prevents the coil from directly contacting and biting the insulating member, thereby protecting the insulating member from damage while maintaining the prepared slot configuration.
Solution Approach 2:
The insulating member is inserted into the slot beforehand and positioned by the cuff support groove before coil insertion. This preliminary positioning ensures the insulating member is correctly placed and protected during the subsequent coil insertion process, preventing damage while maintaining manufacturing efficiency.
3Device complexity
If the guide member structure is simplified, then the device complexity is reduced, but the ability to prevent coil from biting insulating member is compromised
Solution Approach 1:
The guide member is segmented into two functional grooves (cuff support groove and coil guide groove) that work together in a single integrated component. This segmentation provides the necessary protection against biting while maintaining a relatively simple overall structure that is easier to manufacture and install compared to multiple separate components.
Solution Approach 2:
The guide member is designed as a multi-functional component that simultaneously supports the insulating member (via cuff support groove) and guides the coil (via coil guide groove). This multi-functionality protects against biting while maintaining structural simplicity, as one component performs multiple protective and guiding functions.
Data Source
AI summary
A coil insertion guide device includes a positioning jig that positions a stator core; and a guide member that is provided in the positioning jig so as to be able to contact an end face of the stator core in an axial direction. A coil inserted into the slots along the radial direction of the stator core is guided by the guide members. The guide member includes a guide groove. The guide groove includes, on a side close to the end face of the stator core, a cuff support groove that houses and supports a cuff of one of the insulating members that protrudes from the end face of the stator core, and on a side far from the end face, a coil guide groove that protrudes toward an inside of the slot more than the cuff support groove and contacts the coil to guide movement of the coil.