Flat Wire Motor Stator Insulating Sleeve Insertion Device
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Solution Overview
Problem
The existing method for inserting insulating sleeves into wiring slots of flat wire motor stators is inefficient, leading to insulation instability and restricted flexibility in designing winding sizes due to low space factor and difficulties in controlling sleeve specifications.
Innovation Solution
A method and device that pre-process insulating sleeves to match the size of the stator slots, using a feed mechanism, conveying mechanism, clamping mechanism, and guide mechanism to directly insert the sleeves into the slots, ensuring precise fitting and high efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If insulating paper is folded and mechanically cut into small sections to form sleeves, then insulating structures can be created, but the production efficiency is low due to one-by-one insertion and the process takes 5 minutes per slot
Solution Approach 1:
The patent divides the insulating paper into multiple pre-cut sections (first insulating paper section, second insulating paper section, etc.) that can be independently positioned and inserted into different wiring slots. This segmentation allows parallel processing of multiple slots simultaneously, transforming the sequential one-by-one insertion process into a parallel operation that completes all slot insertions within 10-20 seconds.
Solution Approach 2:
The insulating paper sections are pre-cut and pre-positioned on the insulating paper before the actual insertion process. The first insulating paper section is positioned in advance in the first wiring slot area, and the second insulating paper section is positioned in advance in the second wiring slot area. This preliminary positioning eliminates the need for time-consuming on-site folding and cutting, enabling rapid simultaneous insertion into multiple slots.
2Ease of manufacture
If insulating paper is folded into tube shape with seams, then insulating sleeves can be formed, but the insulation performance is compromised due to seams affecting insulation reliability
Solution Approach 1:
Instead of folding a continuous insulating paper into a tube with seams, the patent segments the insulating paper into multiple separate sections (first insulating paper section, second insulating paper section, third insulating paper section) that are directly positioned and inserted into respective wiring slots. Each section acts as an independent insulating sleeve without requiring folding or creating seams, thereby eliminating the insulation compromise caused by seam joints.
Solution Approach 2:
The patent extracts the folding and seam-creation steps from the traditional sleeve formation process. By removing the folding operation entirely and using pre-cut rectangular sections instead, the harmful seams are eliminated. The insulating function is achieved directly through the positioned sections rather than through folded tubes with potential weak points at the seams.
3Reliability
If multiple insulating paper sleeves are inserted into one stator slot, then insulation coverage is improved, but the space factor decreases and flexibility for winding size design is restricted
Solution Approach 1:
The patent assigns dedicated insulating paper sections to specific wiring slots (first section to first slot, second section to second slot, etc.), providing appropriate insulation coverage for each slot without over-filling. This segmented allocation optimizes space utilization in each slot, maintaining the space factor advantages of flat wire motors while ensuring adequate insulation. The method avoids the space waste and design flexibility loss associated with inserting multiple sleeves into single slots.
4Ease of manufacture
If traditional mechanical folding and hot press methods are used, then insulating sleeves can be formed, but the specifications are difficult to control and production time is excessive
Solution Approach 1:
The insulating paper sections are pre-cut to precise dimensions and pre-positioned on the insulating paper before the insertion process. The first insulating paper section is pre-cut and positioned in advance for the first wiring slot, and the second insulating paper section is pre-cut and positioned in advance for the second wiring slot. This preliminary precision cutting and positioning eliminates the specification control difficulties of traditional folding and hot press methods, ensuring consistent and accurate sleeve dimensions while reducing production time to 10-20 seconds.
Data Source
AI summary
An insulation sleeve insertion device for inserting insulating sleeves into wiring slots of a flat wire motor stator, comprising a processing panel, a feeder, a conveying mechanism comprising conveyor belts, a positioning mechanism comprising a limit ring and a positioning turntable, a guide mechanism comprising a plurality of second guide rails, a clamping mechanism comprising a drive rod, a positioning plate set, and a drive mechanism comprising a second driver, wherein the clamping mechanism is configured to insert insulating sleeves into wiring slots of the flat wire motor stator through the guide mechanism.