Hairpin Stator Terminal Supply and Alignment for Faster Welding
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Solution Overview
Problem
Manual supply of terminal assemblies in the welding process for hair pin type stators is inefficient, leading to increased welding time and the need for multiple workers due to the complexity of handling different specifications, which can result in mismatches with the stator models.
Innovation Solution
An automatic supply system comprising a conveyor unit, a terminal supply robot, and a terminal alignment unit that transports, aligns, and loads terminal assemblies into welding jigs, enabling precise and efficient delivery of terminal assemblies of varying specifications to welding units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual supply method is used, then workers can handle terminal assemblies, but welding work time increases and workability decreases
Solution Approach 1:
The terminal assembly supply system is designed to automatically supply terminal assemblies to welding equipment without requiring manual intervention. The system includes a terminal assembly storage unit, a supply robot, and a conveyor that work together to autonomously fetch, transport, and position terminal assemblies, making the system self-sufficient and eliminating dependency on manual operations.
Solution Approach 2:
The patent replaces the manual mechanical supply method with an automated robotic system. The supply robot equipped with a gripper mechanically retrieves terminal assemblies from the storage unit and transfers them to the conveyor, which then transports them to the welding equipment. This substitution of manual mechanical operations with automated mechanical systems resolves the contradiction between ease of operation and time consumption.
2Adaptability or versatility
If multiple workers are used to supply terminal assemblies of different specifications, then all specifications can be handled, but the number of workers increases
Solution Approach 1:
The terminal assembly supply system is designed with multi-functionality to handle various specifications of terminal assemblies. The storage unit can accommodate different types of terminal assemblies, and the supply robot is equipped with adaptive grippers that can adjust to different sizes and shapes. The conveyor system can also accommodate different specifications, enabling a single automated system to perform multiple functions that previously required multiple workers.
Solution Approach 2:
The automated supply system autonomously identifies and supplies the correct specification of terminal assemblies to the welding equipment based on the stator model being processed. The system includes control mechanisms that automatically select the appropriate terminal assembly specification, eliminating the need for multiple workers to manually determine and handle different specifications.
3Productivity
If manual supply is used, then terminal assemblies can be supplied, but mismatches with stator models may occur
Solution Approach 1:
The terminal assembly supply system incorporates feedback mechanisms that continuously monitor and verify the matching between terminal assemblies and stator models. The system receives information about the stator model being processed and automatically adjusts its supply decisions accordingly. This feedback loop ensures that only the correct specification of terminal assemblies is supplied, preventing mismatches while maintaining high supply speed.
Solution Approach 2:
The system performs preliminary verification and preparation of terminal assemblies before they are supplied to the welding equipment. The storage unit is organized with terminal assemblies of different specifications, and the supply robot预先 (in advance) identifies and selects the correct specification based on the stator model requirements. This preliminary action ensures that the correct terminal assembly is ready for supply before the welding process begins, preventing mismatches.
Data Source
AI summary
An automatic supply system of a terminal assembly for a hair pin type stator supplies the terminal assembly to a welding unit welding the stator coil and terminal assembly of the hair pin type stator to each other. The system includes: i) a conveyor unit transporting a terminal supply box storing the plurality of terminal assemblies along a set transport path; ii) a terminal supply robot gripping or releasing at least one terminal assembly of the plurality of terminal assemblies, and loading or unloading the at least one terminal assembly at a set location; and iii) a terminal alignment unit aligning the at least one terminal assembly loaded at the set location by the terminal supply robot.