Hairpin Crown Insertion for Precise Stator Conductor Joining
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Solution Overview
Problem
The existing manufacturing processes for stators and rotors in electrical machines are complex and expensive due to the need for precise alignment of numerous conductors, and there is a risk of damage when inserting pins or hairpins into these machine elements.
Innovation Solution
A device and method for joining electrical conductors, comprising a collection receptacle and a joining device with gripping elements and a pressure element, which allows for the precise insertion of ring arrangements of pins into machine elements like stators or rotors, minimizing damage by controlling the relative movement of the pins during insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional joining methods (soldering, crimping, welding) are used to join electrical conductors, then electrical connection is achieved, but the structural integrity and mechanical strength of the stator are compromised due to additional stresses from assembly processes
Solution Approach 1:
The patent combines the electrical conductor joining function with the stator assembly structure itself. The stator assembly serves dual purposes: as the mechanical housing and as the joining mechanism for electrical conductors, eliminating the need for separate joining operations that would compromise structural strength
Solution Approach 2:
The patent introduces a groove structure as an intermediary element that facilitates electrical conductor connection without requiring traditional joining methods. The groove provides a mechanical interface that maintains both electrical connectivity and structural integrity
2Reliability
If additional joining operations are performed on electrical conductors, then electrical connection is established, but the manufacturing complexity and number of production steps increase
Solution Approach 1:
The patent merges multiple manufacturing functions into a single integrated stator assembly structure. The groove for electrical conductor joining is formed as part of the stator assembly process itself, eliminating the need for separate joining equipment and operations
Solution Approach 2:
The stator assembly is designed to perform multiple functions: mechanical housing, electrical conductor support, and electrical conductor joining. This multi-functionality reduces the overall number of components and manufacturing steps required
3Reliability
If traditional joining methods are used for electrical conductors, then connection is achieved, but production time increases due to additional manufacturing steps
Solution Approach 1:
The groove structure for electrical conductor joining is prepared in advance as part of the stator assembly manufacturing process. This preliminary preparation eliminates the need for time-consuming joining operations during final assembly
Solution Approach 2:
The patent combines the stator assembly manufacturing with the electrical conductor joining preparation in a single process step, allowing both functions to be accomplished simultaneously rather than sequentially
Data Source
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AI summary
The invention relates to a device for joining electrical conductors in a machine element of an electric machine, comprising a collection receptacle (80) for providing an arrangement (20) of one or more crowns, which are formed from electrically conductive hairpins (2), and a joining apparatus (90) for removing the crown arrangement (20) from the collection receptacle (80) and for introducing the crown arrangement (20) into the machine element. An associated method according to the invention comprises the steps: providing an arrangement (20) of one or more crowns of hairpins (2), in a collection receptacle (80); removing the crown arrangement (20) from the collection receptacle (80); and introducing the crown arrangement (20) into the machine element, which is in particular a stator or rotor of an electric motor.