Hairpin Transfer Layout for Fast Stator Core Insertion
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Solution Overview
Problem
Existing methods for arranging conductor parts, particularly plug-in winding elements like hairpins, in a stator core are inefficient and costly, lacking a rapid and effective means to achieve a desired arrangement suitable for gripping and insertion.
Innovation Solution
A device comprising a supply unit, carry-over region, and arrangement unit, utilizing a pick-up unit with a rotational movement to distribute conductor parts in a circumferential direction on concentric circular paths, ensuring quick and reliable arrangement of hairpins or I-pins in radially aligned rows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to arrange conductor parts in a stator core, then the arrangement can be achieved, but the process is inefficient and costly with low productivity
Solution Approach 1:
The device pre-arranges conductor parts in a desired configuration on the arrangement unit before insertion into the stator core. The supply unit feeds conductor parts that are preliminarily positioned in radially aligned rows on concentric circular paths, so that when the arrangement unit rotates, the parts are already in the correct arrangement for stator insertion, eliminating the need for time-consuming manual or sequential positioning during the insertion process.
Solution Approach 2:
The arrangement unit is designed to rotate relative to the supply unit, dynamically transferring conductor parts from the supply unit to the stator core insertion position. This rotational movement enables continuous, high-speed arrangement of conductor parts in the desired configuration, significantly increasing productivity compared to static conventional methods.
2Ease of manufacture
If conductor parts are arranged manually or using conventional equipment, then the arrangement can be achieved, but the process is costly
Solution Approach 1:
The device is designed to automatically arrange conductor parts without requiring manual intervention. The supply unit automatically feeds conductor parts, the arrangement unit automatically positions them in radially aligned rows on concentric circular paths, and the rotational mechanism automatically transfers them to the insertion position. This self-service capability eliminates labor costs and increases production efficiency.
Solution Approach 2:
The invention replaces manual or conventional mechanical arrangement methods with an automated mechanical system featuring a rotating arrangement unit. This substitution of manual operations with an automated rotational mechanism dramatically improves both ease of manufacture and productivity, making the process more efficient and cost-effective.
3Manufacturing precision
If conductor parts are arranged in radially aligned rows on concentric circular paths, then the desired arrangement for stator insertion is achieved, but complex device structure is required
Solution Approach 1:
The arrangement unit utilizes concentric circular paths (curved geometry) to arrange conductor parts in radially aligned rows. This circular arrangement naturally corresponds to the radial geometry of stator cores, achieving precise positioning for insertion. The rotational movement of the arrangement unit along these circular paths simplifies the mechanism compared to attempting to create straight-line or irregular patterns, as the rotation inherently provides the required radial alignment.
Data Source
AI summary
The invention relates to a device and a method for transferring conductor parts, in particular plug-in winding elements bent into a U-shape, also known as hairpins, into a desired arrangement.