Floating Conductor Guide for Stator Core Insertion
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Solution Overview
Problem
Existing electric conductor insertion apparatuses face challenges in guiding electric conductors into slots of a stator core with varying thickness, leading to potential damage to insulating paper and positional skew issues.
Innovation Solution
An electric conductor insertion apparatus featuring a conductor guide member that is floatable in the axial direction, supported by a support body that can displace to accommodate varying stator core heights, ensuring proper guidance and pressing of insulating paper against the slot walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the stator core is formed by layering electromagnetic steel sheets with non-uniform thickness, then the manufacturing process is simple and cost-effective, but the layered thickness varies within a tolerance range depending on the region
Solution Approach 1:
The conductor guide member is designed to be movable in the axial direction, allowing it to dynamically adjust its position according to the actual height of the stator core in different regions. This dynamic adjustment capability enables the guide member to maintain proper guidance function despite variations in stator core thickness, resolving the contradiction between simple manufacturing and thickness uniformity.
2Productivity
If the first expansion plate and the second expansion plate are simultaneously inserted into respective slots of the stator core with height variation, then the insertion process is efficient, but the guidance by these plates only continues until the leg portions are partway into the slots in low regions
Solution Approach 1:
The conductor guide member is configured to move in the axial direction, enabling it to maintain continuous contact with the leg portions throughout the insertion process. This dynamic positioning ensures that guidance accuracy is maintained even when inserting conductors into slots of varying heights, resolving the contradiction between insertion efficiency and guidance accuracy.
Solution Approach 2:
The support body is divided into multiple support portions positioned at different axial locations, each capable of independently supporting the conductor guide member. This segmentation allows different portions of the guide member to adapt to different stator core heights in different regions, maintaining both productivity and precision.
3Manufacturing precision
If a pressing element is used to make the stator core height uniform, then the conductor insertion guidance is improved, but the equipment complexity and cost increase
Solution Approach 1:
Instead of using a complex pressing mechanism to uniformly compress the stator core, the invention employs a simple movable conductor guide member that dynamically adapts to the existing height variations. This approach achieves the same guidance improvement without adding equipment complexity or cost.
Solution Approach 2:
The conductor guide member automatically adjusts its position based on the actual stator core height, eliminating the need for external pressing mechanisms. The system uses the natural height variations of the stator core and allows the guide member to self-adjust, thereby simplifying the overall equipment while maintaining precision.
4Device complexity
If the conductor guide member is made fixed in position, then the structural simplicity is maintained, but the guidance function is compromised when stator core height varies
Solution Approach 1:
The conductor guide member is designed with movable support portions that can adjust their axial positions independently. This dynamic structure allows the guide member to maintain proper guidance function despite stator core height variations, while adding minimal complexity to the overall system.
Data Source
AI summary
An insertion apparatus includes a conductor guide member that guides a prescribed region of an electric conductor to a slot of a stator core, and a support body that supports the conductor guide member. In this configuration, the conductor guide member can float in an axial direction of the stator core.