Conductive Pin Assembly for Precise Winding Transfer Alignment
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Solution Overview
Problem
Existing assembly processes for conductive pins in rotating electric machines are inefficient, leading to increased manufacturing costs and the risk of poor pin positioning, which can result in short circuits due to enamel breaks.
Innovation Solution
A novel assembly process for conductive pins in a transfer device, where the pins are divided into subsets and manipulated through specific stages such as layout, uprising, insertion, and lowering to achieve precise alignment and insertion without the need for global twisting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a global twisting step is used to twist all conductive pins simultaneously, then the pins can be positioned on a circle of the correct diameter facilitating transfer, but the twisting is not precise and can cause breaks in the enamel covering the copper forming the conductive pins which can cause short circuits
Solution Approach 1:
The patent divides the conductive pins into two subsets (first subset and second subset) and processes them separately through distinct operational phases. The first subset is positioned during a first part of the operation, while the second subset is positioned during a second part, allowing individualized control over each pin's twisting and positioning to achieve both precision and ease of transfer.
2Manufacturing precision
If each pin is twisted individually in a unitary twisting step, then better control of final dimensions and avoidance of enamel breakage is achieved, but it is not possible to position the pins directly in their final position for insertion into the coiled part body during an automatic process
Solution Approach 1:
The patent segments the pin positioning process into two distinct parts: a first part where the first subset of pins is positioned, and a second part where the second subset of pins is positioned. This segmentation allows the process to maintain precision through individualized handling while achieving automation by structuring the operations in manageable, repeatable phases.
Solution Approach 2:
The patent performs preliminary positioning actions on the first subset of pins before the second subset is processed. This preliminary action establishes a foundation that facilitates the subsequent positioning of the second subset, enabling the overall process to achieve both precision and efficiency through structured sequencing.
3Ease of manufacture
If pins are positioned by radial displacement between a large and a small diameter tool, then pins can be transferred from the twisting tool to the body of the wound part, but in certain winding configurations the nesting of pins and large number of layers can complicate or make this method impossible, increasing assembly time and manufacturing cost
Solution Approach 1:
The patent divides the pins into two subsets and positions them in separate operational phases. This segmentation simplifies each individual positioning operation, making them feasible even for complex winding configurations with multiple layers and nested pins, while maintaining overall productivity through systematic sequencing.
Solution Approach 2:
The patent employs dynamic, adaptive positioning operations that can adjust to different winding configurations. The method is designed to handle varying numbers of layers and nested pins by flexibly managing the two subsets of pins through controlled operational phases, rather than relying on fixed radial displacement between rigid tool diameters.
Data Source
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AI summary
The invention relates to a method for assembling conductive pins in a transfer device for forming an electrical winding (24) for a wound component of a rotary electric machine (10). A first part (A) of the method (120) comprises at least one supply step (122) comprising arranging the pins of a first assembly of pins (80) in lateral spaces (43) in the transfer device (40); and a second part (B) comprises a raising step (130) in which the pins of a first sub-assembly (80a) are moved so as to create an insertion space (82); an insertion step (131) in which the pins of a second assembly (81) are inserted into the insertion space (82); and a lowering step (132) in which the pins of the first sub-assembly (80a) are moved so as to be circumferentially aligned with the conductive pins of the second assembly (81).