Hairpin Stator Slot Insertion Using a Radial-Shift Template
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing stators with hairpin conductors are complicated, as they often require additional deformation steps or are limited in flexibility regarding the number of layers and types of conductors used, leading to inefficiencies in insertion and assembly.
Innovation Solution
A method and apparatus utilizing a stator core template with larger slots to facilitate the insertion and movement of hairpin conductors, allowing for easy formation of multiple layers and the use of different conductor types, by initially positioning conductors at a first location and then moving them radially to a second position, avoiding collisions and jamming, and using a gripper and presser for efficient transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hairpin conductors are inserted directly into stator core slots in their final shape, then insertion precision is improved, but device complexity increases due to collision between overlapping parts
Solution Approach 1:
The insertion process is segmented into two distinct phases: first inserting conductors into a template with larger slots to avoid collisions, then transferring them to the final stator core. This segmentation allows each phase to be optimized independently, resolving the contradiction between precision and complexity.
Solution Approach 2:
A template with larger slots serves as an intermediary device during the insertion process. This mediator allows conductors with overlapping bridges to be positioned without collision, and subsequently transferred to the final stator core slots, achieving precise insertion without direct complex manipulation.
2Adaptability or versatility
If hairpin conductors are deformed after insertion into slots, then adaptability is improved, but manufacturing complexity increases due to additional twisting steps
Solution Approach 1:
The conductors are pre-shaped outside the stator core to their final configuration before insertion. This preliminary action eliminates the need for post-insertion deformation operations, reducing manufacturing complexity while maintaining the ability to accommodate different conductor types through flexible pre-shaping processes.
3Productivity
If multiple layers of hairpin conductors are assembled outside the stator core, then productivity is improved, but device complexity increases due to limited flexibility in layer formation
Solution Approach 1:
The template with enlarged slots serves multiple functions: it facilitates insertion of conductors, enables formation of multiple layers, and accommodates different conductor types all in one device. This multi-functionality increases productivity without requiring separate complex assembly systems for each function.
Solution Approach 2:
The template provides additional spatial dimension with larger slot dimensions, allowing conductors to be arranged in multiple layers and positions before final insertion. This dimensional freedom enables efficient multi-layer assembly while maintaining flexibility for different conductor configurations.
4Adaptability or versatility
If sub-groups of hairpin conductor nests are merged before insertion, then adaptability is improved, but loss of time increases due to additional merging steps
Solution Approach 1:
Multiple hairpin conductors and their nests are merged together within the template structure during the insertion process itself, rather than requiring separate pre-merging steps. This integration of merging into the insertion operation reduces time loss while maintaining adaptability for different conductor arrangements.
Data Source
Figure 1~2b
Figure 3~4
Figure 5~6
AI summary
A method and an apparatus are provided for manufacturing a stator with a plurality of hairpin conductors. For inserting the hairpin conductors (15, 15') into the slots (11) of a stator core (12) a stator core template (22) is provided. Hairpin conductors (15) are axially inserted into slots (21) of the stator core template (22) such that the hairpin conductor (15) is arranged at a first position (P1) within said slot (21). The hairpin conductor (15) is then moved within said slot (21) to a different position (P2). A complete nest (20) of hairpin conductors (15) formed within the stator core template (22) is then transferred to the stator core (12).