Rotary Winding Pin Insertion Using Guided Segment Transfer
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Solution Overview
Problem
The existing methods for inserting conductive pins into the wound parts of rotary electric machines are complex, prone to errors, and costly due to the need for multiple tools and the risk of enamel breakage, which can lead to short-circuits and increased manufacturing time.
Innovation Solution
A method and assembly using a transfer device with a spindle body and guide strips to precisely position and insert conductive pins into slots, eliminating the need for additional clamps and simplifying the process by guiding the pins in a circumferential and radial direction, ensuring accurate alignment and reducing the risk of contact with the machine body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an overall twisting step is used to twist all conductive pins simultaneously, then the pins can be positioned on a circle of the correct diameter and transferred directly to the body, but the twisting precision is poor and enamel breakage occurs causing short-circuits
Solution Approach 1:
The patent divides the conductive pin structure into two separate conductive segments that are inserted independently into the body, rather than twisting a single pin. This segmentation allows each segment to be positioned and inserted separately, achieving both high precision and efficiency without the need for twisting operations that cause enamel breakage.
2Manufacturing precision
If each pin is individually twisted in a single twisting step, then twisting precision improves and enamel breakage is avoided, but additional tools and steps are required increasing complexity
Solution Approach 1:
The patent extracts the twisting operation entirely from the process by using two separate conductive segments that are inserted directly into the body without any twisting. This eliminates the need for twisting tools and steps, reducing process complexity while maintaining high precision through direct insertion.
3Measurement precision
If multiple tools are used to place pins in a larger diameter tool and then transfer them to the body, then pin positioning is achieved, but the method becomes more complex and manufacturing time increases
Solution Approach 1:
The patent performs preliminary positioning of the two conductive segments on the insertion device before insertion, ensuring they are correctly aligned with the slots in the body. This preliminary action eliminates the need for subsequent transfer operations between multiple tools, reducing manufacturing time while maintaining positioning accuracy.
Data Source
AI summary
A method for inserting conductive pins from a transfer device to a body of a wound part in order to form an electrical winding of a wound part of a rotary electric machine. The method includes a preparation step, in which the conductive pins are arranged in the spindle body, and a step of positioning the spindle body relative to the body of the wound part. A guide step arranges a guide device to guide the conductive segments in a circumferential and/or radial direction, and a transfer step inserts conductive segments into the corresponding slots.