Copper Bar Assembly Device for Electric Machine Rotor Insertion
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Solution Overview
Problem
The assembly of copper rods into rotor and stator elements in electrical machines is hindered by high cycle times and component damage due to manual or semi-automated production methods, leading to increased reject rates, particularly with hairpin technology where precise positioning is challenging.
Innovation Solution
An assembly device featuring a component receiving element, an alignment unit, and slide elements that allow simultaneous axial insertion of multiple copper rods into receiving slots, with precise alignment and spring-loaded pressing units to ensure accurate positioning and prevent jamming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual or semi-automatic production methods are used for inserting copper rods, then ease of operation is maintained, but productivity is reduced due to high cycle times
Solution Approach 1:
The device divides the insertion process into distinct functional segments: the alignment unit prepares and positions copper rods, while the slide element executes the insertion motion. This segmentation allows each component to be optimized for its specific function, enabling automated high-speed operation while maintaining operational simplicity through modular design
Solution Approach 2:
The alignment unit serves as an intermediary component between the copper rod supply and the insertion point. It pre-positions multiple copper rods in precise alignment with the receiving slots, enabling the slide element to insert multiple rods simultaneously in one motion, thereby dramatically increasing productivity without complicating the overall operation
2Productivity
If automated insertion is implemented to increase productivity, then productivity improves, but manufacturing precision deteriorates due to difficulty in positioning copper rods accurately
Solution Approach 1:
The alignment unit performs preliminary positioning of copper rods before the actual insertion process. By pre-aligning multiple copper rods with the receiving slots in advance, the system ensures that when the slide element moves, the rods are already in the correct positions, maintaining manufacturing precision while enabling simultaneous insertion of multiple rods for high productivity
Solution Approach 2:
The device replaces manual positioning operations with a mechanically precise alignment unit that uses guide structures and positioning features to automatically align copper rods with receiving slots. This mechanical substitution eliminates human positioning errors while maintaining the simplicity of automated operation
3Productivity
If multiple copper rods are inserted simultaneously to reduce cycle time, then productivity improves, but manufacturing precision worsens due to narrow gap dimensions requiring exact positioning
Solution Approach 1:
The alignment unit segments the positioning function from the insertion function. It independently pre-positions each copper rod in precise alignment with its corresponding receiving slot, then the slide element executes simultaneous insertion. This segmentation allows exact positioning of multiple rods without compromising precision, even with narrow gap dimensions
Solution Approach 2:
The alignment unit is designed to self-align copper rods using integrated guide structures and positioning features. The copper rods are automatically positioned by the alignment unit's geometry without requiring external positioning mechanisms, ensuring exact alignment for simultaneous insertion while maintaining system simplicity
4Ease of manufacture
If copper rods are inserted laterally into receiving grooves as required, then the insertion process can proceed, but ease of operation deteriorates due to difficulty in fitting the assembly device with copper rods
Solution Approach 1:
The alignment unit acts as an intermediary that receives copper rods and pre-positions them in the correct orientation and location. By preparing the copper rods in advance with proper alignment, the slide element can then easily execute the lateral insertion into receiving grooves, making the overall process easier to operate while maintaining the required lateral insertion path
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The invention relates to an assembly device for simultaneously inserting a plurality of copper bars into receiving grooves of a rotor element and/or of a stator element of an electric machine in an axial direction A.