Conductive Pin Transfer Assembly for Enamel-Safe Winding Insertion
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Solution Overview
Problem
The existing process for inserting conductive pins into the coil body of rotating electric machines is complex, prone to errors, and can cause breaks in the enamel coating, leading to short circuits. This complexity increases manufacturing time and costs.
Innovation Solution
A transfer device with a spindle body and guidance strips is used to arrange and insert conductive pins into the coil body. The process includes a preparation stage, positioning stage, guide stage with insertion and smoothing phases, and a transfer stage for axial insertion and radial support management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a global twisting step is used to twist all conductive pins simultaneously, then the pins can be positioned on a circle corresponding to their final position, but this causes breaks in the enamel covering the copper which can lead to short circuits
Solution Approach 1:
The patent divides the twisting operation into individual pin-level actions rather than a global simultaneous twist. Each pin is twisted and positioned separately using the transfer device, which holds pins one by one in lateral spaces and transfers them individually to the wound part body. This segmentation prevents the enamel breakage caused by global twisting while maintaining positioning efficiency.
Solution Approach 2:
The transfer device performs preliminary positioning of conductive pins in lateral spaces of the pin body before final insertion into the wound part body. The pins are pre arranged in the correct circumferential positions and then transferred axially, eliminating the need for post-positioning adjustments that could damage the enamel coating.
2Manufacturing precision
If individual twisting of each pin is performed, then better control of final dimensions and avoidance of enamel breakage is achieved, but it is not possible to position pins directly in their final position during automatic processes
Solution Approach 1:
The patent merges the individual twisting operation with the positioning function by integrating both capabilities into a single transfer device. The device holds each pin, performs the twist individually, and simultaneously positions it in the correct lateral space corresponding to its final position in the wound part body. This combination eliminates the need for separate positioning tools and steps.
Solution Approach 2:
The transfer device is designed as a multi-functional tool that performs multiple operations: holding the pin, twisting it individually, positioning it circumferentially, and transferring it axially to the final position. This universal device replaces what would otherwise require multiple specialized tools, reducing overall process complexity despite the precision requirements.
3Ease of operation
If several tools are used for placing and transferring pins, then the pins can be positioned and inserted, but the process becomes complex, manufacturing time increases, and the risk of tool failure increases
Solution Approach 1:
The patent combines multiple separate tools (positioning tool, transfer clamp, insertion device) into a single integrated transfer device. This device performs all functions: holding pins in lateral spaces, positioning them circumferentially, and transferring them axially into the wound part body. This consolidation simplifies the overall process and reduces the number of tool changes or transfers required.
Solution Approach 2:
The transfer device is designed as a universal tool that can handle all aspects of pin insertion: it serves as the positioning fixture, the transfer mechanism, and the insertion device. This multi-functional approach eliminates the need for multiple specialized tools, reducing process complexity and the risk of failures associated with multiple tool interfaces.
Data Source
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AI summary
The invention provides a method for inserting conductive pins from a transferring device into a wound-part body to form an electrical winding (24) of a wound part of a rotary electric machine (10). The inserting method (100) comprises: a preparing step (101) in which the conductive pins are arranged in the shaft body (41); a step (102) of positioning the shaft body with respect to the wound-part body (21); a guiding step (103) in which a guiding device (62) is arranged to guide conductive segments (19) in a circumferential and/or radial direction; and a transferring step (104) in which the conductive segments are inserted into corresponding slots.