Epoxy Coated Stator Hairpin Measurement Gauge
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Solution Overview
Problem
Existing measurement gauges fail to accurately measure the dimensions of epoxy coated electrical components in stators within predetermined tolerance ranges, particularly in the context of electric machines like electric motors and generators, where precise dimensions are crucial for performance and reliability.
Innovation Solution
A measurement gauge comprising a height gauge part with a base surface, legs, and height checking surfaces, and a diameter gauge part with annular and variable thickness designs, which are configured to securely attach to the stator core and measure the height and diameter of epoxy coated components, ensuring they fall within specified tolerance ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing measurement gauges are used to measure epoxy coated electrical components, then the measurement process is simple, but the measurement precision is insufficient to determine if components are within predetermined tolerance ranges
Solution Approach 1:
The measurement gauge is divided into multiple independent gauge parts, each responsible for measuring specific dimensions (height, outer diameter, inner diameter) of the epoxy coated components. This segmentation allows each part to be optimized for its specific measurement function, improving overall measurement precision while maintaining manageable complexity through modular design.
Solution Approach 2:
The gauge incorporates checking surfaces at multiple predetermined distances (first, second, and third distances) from the base surface, creating multiple measurement reference planes. This multi-dimensional approach enables comprehensive verification of component dimensions within tolerance ranges, significantly enhancing measurement precision beyond single-plane gauges.
2Adaptability or versatility
If a single gauge part is used, then the device complexity is low, but the adaptability to measure different dimensions of epoxy coated components is insufficient
Solution Approach 1:
The measurement gauge is designed as a universal multi-functional device where multiple gauge parts (height gauge part, outer diameter gauge part, inner diameter gauge part) work together to measure various dimensions of different epoxy coated electrical components. Each gauge part can be positioned and used independently or in combination, providing versatile measurement capabilities across multiple parameters.
Solution Approach 2:
The gauge incorporates movable and adjustable elements, including the ability to position gauge parts at different locations and orientations on the stator core. The checking surfaces are arranged to accommodate variations in component dimensions and positions, allowing the gauge to adapt dynamically to different measurement requirements while maintaining a fixed structural framework.
Data Source
AI summary
A measurement gauge for a stator that includes a height gauge part having at least one base surface, legs, and a height checking surface. The base surface faces in a first direction to define a base plane configured to abut an end surface of a core of the stator. The legs are spaced apart in a circumferential direction about an axis and extend in the first direction from the base surface. The legs are configured to be received in holes defined by the core of the stator. The height checking surface is parallel to the base plane and spaced apart therefrom by a predetermined distance. The height checking surface having an annular shape disposed about the axis.