Hairpin Insertion with 3D Head Forming for Faster Stator Assembly
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Solution Overview
Problem
Current methods for molding hairpins for electric vehicle motors are either slow due to their ability to handle multiple types or limited in productivity due to handling only single types, necessitating a solution that enhances both speed and versatility in the production process.
Innovation Solution
An apparatus comprising a clamping unit with a robot arm and a mold unit that includes a pair of reciprocally driven clampers and a molding jig system, allowing for simultaneous molding and insertion of hairpins into a stator core, enabling efficient three-dimensional formation and alignment of hairpins for improved productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If CNC molding method is used to handle various types of hairpins, then versatility is improved, but production speed decreases (six seconds per hairpin)
Solution Approach 1:
The mold unit is designed with a detachable coupling mechanism that allows different mold units to be interchangeably mounted on the same clamping unit. The connection bracket and fixing chuck provide a universal interface that can accommodate multiple types of mold units, enabling the system to handle various hairpin types without requiring multiple dedicated molding machines.
Solution Approach 2:
The system employs dynamic tooling where the mold unit can be quickly detached and replaced on the clamping unit. The fixing chuck with fixing pins and fixing block enables rapid changeover between different mold units, allowing the production line to adapt to different hairpin types while maintaining high production speed.
2Productivity
If press molding method is used for faster production speed, then productivity is improved (three seconds per hairpin), but versatility deteriorates (handling only single type of hairpins)
Solution Approach 1:
The clamping unit serves as a universal base that can accommodate multiple different mold units through the detachable coupling mechanism. The connection bracket and fixing chuck provide standardized interfaces that enable any mold unit to be mounted on any clamping unit, giving the fast press molding system the versatility to handle various hairpin types.
Solution Approach 2:
Different mold units are prepared in advance and can be quickly swapped on the clamping unit when production requirements change. The detachable coupling mechanism allows for pre-configured mold units to be rapidly exchanged, enabling the system to maintain high production speed while adapting to different hairpin types as needed.
3Manufacturing precision
If separate molding and insertion processes are used, then manufacturing precision is improved, but cycle time increases
Solution Approach 1:
The system merges the molding and insertion operations into a single integrated process. The mold unit performs the molding operation and then directly transfers the molded hairpin to the insertion position, eliminating the need for separate handling and transfer operations. This integration maintains molding precision while significantly reducing the overall cycle time.
Solution Approach 2:
The molding and insertion operations are performed in continuous sequence without interruption. The mold unit completes the molding operation and immediately proceeds to the insertion operation, maintaining continuous productive action throughout the cycle and eliminating idle time between operations.
Data Source
AI summary
A method can be used for inserting a hairpin in a stator core. The method includes unwinding a coil spiral-wound on an uncoiler, forming a decoated portion by decoating a predetermined portion on the coil, bending the coil in multiple stages to two-dimensionally form a leg portion and a head portion of a hairpin, cutting the coil formed with the leg portion and the head portion by a predetermined length, and moving the hairpin to be inserted into a stator core while three-dimensionally forming the head portion.