Coil Insertion Device Radial Groove Transfer Block
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Solution Overview
Problem
The existing method for inserting coils into stator cores, as described in Japanese Patent No. 4813171, faces issues with deformation of radial plates and inefficiency due to increased turn angles, leading to mechanical stress and potential damage during the coil insertion process.
Innovation Solution
A coil insertion method and device that utilize a transfer block with radially arranged holding grooves to spirally overlap U-phase, V-phase, and W-phase coils, allowing them to be pressed radially outward and inserted into the stator core slots efficiently, reducing mechanical stress and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the jig is rotated a large angle to align the second holding groove group with the corresponding slots, then the coils can be inserted into the slots, but the radial plates deform and mechanical stress increases
Solution Approach 1:
The holding groove groups are divided into multiple subsets arranged at different radial positions on the jig. Each subset can be independently aligned with corresponding slot groups on the stator core, eliminating the need for large-angle rotation and preventing radial plate deformation.
Solution Approach 2:
The solution transitions from a single-plane rotation approach to a multi-radial-position arrangement. By distributing holding groove groups across different radial positions, the system achieves alignment capability without requiring large rotational angles, thus avoiding mechanical stress on radial plates.
2Productivity
If the jig is designed with multiple holding groove groups arranged for sequential insertion, then coil insertion capability is improved, but the turn angle increases causing forcing and deformation
Solution Approach 1:
The holding groove groups are segmented into multiple subsets positioned at different radial locations. Each subset handles a specific group of slots, allowing parallel or sequential insertion without requiring the entire jig to rotate through large angles, thereby maintaining insertion precision.
Solution Approach 2:
The radial plate structure acts as an intermediary that maintains the relative positions of holding grooves while allowing minimal adjustment. This mediator enables the holding groove groups to align with slots without forcing the coils, preventing deformation while maintaining insertion capability.
3Device complexity
If a single jig structure is used for inserting multiple coils, then device complexity is reduced, but the turn angle requirement increases causing forcing and potential damage
Solution Approach 1:
The single jig is segmented into multiple holding groove groups positioned at different radial positions. This segmentation allows each group to independently align with corresponding slots without requiring large rotations, reducing mechanical stress on coils while maintaining a relatively simple overall jig structure.
Solution Approach 2:
The jig design incorporates dynamic alignment capability where holding groove groups can be positioned to match slot arrangements. This dynamic positioning allows the system to adapt to different insertion requirements without forcing coils, reducing mechanical stress while maintaining structural simplicity.
Data Source
AI summary
A coil insertion method includes winding U-phase, V-phase, and W-phase coils; inserting the U-phase, V-phase, and W-phase coils into a transfer block, such that the U-phase, V-phase, and W-phase coils are held in a plurality of holding grooves of the transfer block so as to spirally overlap, the transfer block having a columnar shape, and the holding grooves being formed in radial fashion around the transfer block so as to open from a center part of the transfer block toward an outer periphery thereof; inserting the transfer block into an inner periphery of the stator core; and pushing a side part of the coils held in the holding grooves radially outward toward predetermined slots of the stator core so that the coils are inserted from the inner peripheral side of the stator core into the slots.