Coil Insertion Tool Transfer System for Dynamo Electric Machines
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Solution Overview
Problem
Inaccurate positioning of coils during transfer and insertion in dynamo-electric component manufacturing systems leads to manufacturing inefficiencies, increased production time, and suboptimal use of manufacturing space, necessitating improved accuracy and flexibility in winding and insertion station layouts.
Innovation Solution
The manufacturing system integrates winding and insertion stations along a transfer system with a platform that supports insertion tools, allowing for efficient transfer and positioning through a moveable platform assembly with support members and load devices, enabling accurate and flexible placement of coils within stator cores without disturbing their conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the insertion tool is transferred from the winding station to the insertion station by a pallet conveyor system or rotating table solution, then the coils can be transported between stations, but the position of the coils on the insertion tool becomes inaccurate during transfer stages
Solution Approach 1:
The transfer system is segmented into multiple support members (at least three support members) that independently support the insertion tool at different locations. This segmentation allows each support member to maintain the tool's position independently, preventing distortion and maintaining coil positioning accuracy during transfer between stations.
Solution Approach 2:
The support members act as intermediaries between the insertion tool and the transfer mechanism. These intermediaries provide stable, distributed support that prevents the insertion tool from shifting or distorting during transfer, thereby maintaining the precise positioning of coils without requiring direct contact between the transfer mechanism and the coils.
2Manufacturing precision
If the coils are positioned on the insertion tool with high accuracy at the winding station, then the coil insertion quality is improved, but the positioning accuracy is lost during transfer movements
Solution Approach 1:
Instead of attempting to maintain the insertion tool's position through active control during transfer, the system inverts the approach by providing passive, distributed support through multiple support members. This inverted approach allows the tool to maintain its position naturally during transfer without active intervention, preserving both accuracy and efficiency.
3Ease of manufacture
If the winding and insertion stations are located at a certain distance from each other, then the operations can be performed in distinct stations, but the transfer time increases and production efficiency decreases
Solution Approach 1:
The transfer system is designed to be dynamic and adaptable, with support members that can adjust to the insertion tool's position and orientation. This dynamic support system enables efficient transfer movements that minimize transfer time while maintaining operational independence of the winding and insertion stations, thereby improving overall productivity.
Data Source
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AI summary
Manufacturing Systems for winding and inserting coils in dynamo-electric machine components require insertion tools for carrying the coils between winding stations and insertion stations. The insertion tools are transferred by means of moveable support portions that become aligned with loading devices present at the stations. The station layout is such that the stations can be disposed on one side or on two sides of the solution for transferring the insertion tools. Transfer operations of the insertion tools avoid altering the position and conditions of the coils on the insertion tools and can allow high speed of the motions to transfer the insertion tools between the stations