Coil Insertion Device Radial Pushing Mechanism

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Solution Overview

Problem

The existing coil insertion methods for dynamo-electric machines risk deteriorating the alignment of coils during insertion due to orthogonal insertion directions of pushers and coil side portions, making accurate placement into stator core slots challenging.

Innovation Solution

A coil insertion device with delivery jigs featuring slits for parallel side portions and a pushing block mechanism that moves in the depth direction of the slits to align and insert the coils into slots, ensuring precise alignment without damaging the wire rod.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If pushers are inserted from the tip ends to the holding grooves in the longitudinal direction, then the coil side portions can be pushed out radially outwards, but the alignment of the wire rod is deteriorated because the insertion direction and moving direction are orthogonal

Engineering Contradiction:

Improvecoil insertion operationVSAvoidalignment of wire rod

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

Instead of pushing the coil side portions from the tip end in the longitudinal direction of the holding groove, the patent inserts the pusher from the radial direction (from the opening of the holding groove toward the bottom). This reverses the insertion direction to be parallel with the moving direction of the coil side portions, eliminating the orthogonal conflict that causes alignment deterioration.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The pusher is preliminarily inserted into the holding groove from the radial direction before the coil assembly operation. This preliminary positioning ensures that when the pusher pushes the coil side portions, the force is applied in the correct direction (parallel to the groove depth direction), maintaining wire rod alignment throughout the process.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If plate-shaped pushers with inclined side surfaces are used to push coils out, then the coils can be pushed radially outwards, but parts of the wire rod are moved together with the pushers in the insertion direction, making accurate insertion into slots difficult

Engineering Contradiction:

Improvecoil pushing efficiencyVSAvoidinsertion accuracy into slots

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent inverts the pusher insertion direction from the conventional longitudinal approach to a radial approach. The pusher is inserted from the radial direction (through the opening of the holding groove toward its bottom) rather than from the tip end. This ensures the pusher's movement direction is parallel to the coil side portions' movement direction, preventing wire rod displacement in the orthogonal direction and enabling accurate slot insertion.

Inventive Principle:

Principle #13The other way round (Inversion)

3Device complexity

If the insertion direction of pushers is orthogonal to the moving direction of coil side portions, then the pushing mechanism is simple, but the wire rod alignment is deteriorated

Engineering Contradiction:

Improvepushing mechanism structureVSAvoidalignment degree of wire rod

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent applies the inversion principle by changing the pusher insertion direction from orthogonal (longitudinal) to parallel (radial) with respect to the coil side portions' movement direction. The pusher is inserted through the opening of the holding groove toward its bottom, ensuring its movement is parallel to the groove depth direction. This maintains wire rod alignment while keeping the pushing mechanism relatively simple.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS11705792B2Coil insertion device and coil insertion method

Publication Date: 2023.07.18 NITTOKU CO LTD

AI summary

A coil insertion device includes: a pair of delivery jigs respectively formed with slits into which a pair of side portions of a coil that are parallel with each other can be inserted; and a side portion inserting mechanism configured to push out the side portions inserted into the slits from the slits to insert the side portions into slots of a stator core, the slots facing the slits, the side portion inserting mechanism has: pushing blocks inserted into the slits; and a pushing block moving mechanism configured to move the pushing blocks in a depth direction of the slits.