Copper Rod Positioning for Hairpin Electric Machines
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Solution Overview
Problem
The assembly process of copper rods in hairpin technology for electric machines is time-consuming and prone to errors due to high positional accuracy requirements, leading to high reject rates, especially in manual or semiautomatic production methods, where overlapping and different span lengths of copper rods complicate the prepositioning and assembly process.
Innovation Solution
A positioning device with a rotary body and guide channels that allows for pivot motion of U-shaped copper rods, enabling simultaneous loading and prepositioning without overlap, using locking means to secure leg portions in receiving grooves and a rotary drive mechanism to rotate the rods into position, facilitating both manual and automated loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual or semiautomatic production methods are used for assembling copper rods, then flexibility in handling different copper rod configurations is maintained, but cycle time increases and reject rate increases due to high positional accuracy requirements
Solution Approach 1:
The patent changes the geometric parameters of the positioning device, specifically the angle between guide channels and receiving grooves, to enable automatic positioning of copper rods with different spans. This allows the device to handle various copper rod configurations automatically without manual intervention, resolving the contradiction between operational flexibility and productivity.
2Ease of operation
If manual or semiautomatic production methods are used for assembling copper rods, then flexibility in handling different copper rod configurations is maintained, but reject rate increases due to high positional accuracy requirements
Solution Approach 1:
The positioning device enables copper rods to self-position automatically through the guide channels and receiving grooves mechanism. The device structure itself performs the positioning function without requiring manual intervention, ensuring consistent positional accuracy and reducing reject rates while maintaining flexibility for different copper rod configurations.
3Ease of manufacture
If copper rods are prepositioned with overlapping arrangements, then subsequent assembly becomes simpler, but damage to copper rods increases during handling
Solution Approach 1:
The positioning device performs preliminary positioning of copper rods in the correct final configuration before assembly. By prepositioning copper rods in their exact assembly positions using the guide channels and receiving grooves, the device eliminates the need for subsequent manual adjustments and prevents damage that would occur during overlapping handling operations.
4Adaptability or versatility
If copper rods with different spans are used to realize different wiring diagrams, then electrical machine functionality is improved, but prepositioning complexity increases
Solution Approach 1:
The positioning device is designed with guide channels and receiving grooves at specific angular relationships that enable it to handle copper rods with different spans universally. The device can accommodate various copper rod configurations without requiring different positioning mechanisms, thereby supporting different electrical machine functionalities while maintaining simple prepositioning operations.
Data Source
AI summary
A positioning device may be used to peripherally position copper rods about a center axis that defines an axial direction. Each of the copper rods may be generally U-shaped and may have a first leg portion and a second leg portion. The positioning device may include a positioning body, a rotary body, locking means, and a rotary drive. Grooves of an outer peripheral surface of the positioning body may receive the first leg portions of the copper rods, which can be locked in place by the locking means. The rotary body may be rotatable about the positioning body and may include guide channels that receive the second leg portions of the copper rods. The rotary drive can cause the rotary body and the positioning body to rotate relative to one another, to pivot the second leg portions inwardly into the grooves of the positioning body.