Hairpin Winding Transfer Assembly for Precise Pin Positioning
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Solution Overview
Problem
Existing assembly processes for conductive pins in rotating electric machines face challenges such as imprecise positioning, risk of enamel breaks leading to short circuits, and increased assembly time and cost due to complex winding configurations.
Innovation Solution
The proposed assembly process utilizes a transfer device with a spindle body and radially extending guide strips to simplify the assembly of conductive pins. This process includes arrangement, power, and rotation stages, allowing for automatic grouping and precise positioning of pins, reducing the risk of errors and enamel breaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a global twisting step is used to twist all conductive pins simultaneously, then the pins can be positioned on a circle of correct diameter facilitating transfer, but the twisting is imprecise and causes breaks in the enamel covering leading to short circuits
Solution Approach 1:
The patent divides the twisting operation into individual pin-level actions rather than a global simultaneous twist. Each pin is twisted separately by a twisting element that acts on single pins as they are fed from the feed device, ensuring precise control over each pin's twisting angle and position while maintaining continuous production flow.
Solution Approach 2:
The pin grouping and preliminary positioning are performed in advance in the feed device before the pins reach the transfer location. This preliminary arrangement ensures that pins are correctly oriented and grouped before the individual twisting action, facilitating smoother transfer and reducing the risk of enamel breakage during the twisting process.
2Manufacturing precision
If each pin is twisted individually in a unitary twisting step, then twisting precision improves and enamel breakage is avoided, but pins cannot be directly positioned in their final position for insertion
Solution Approach 1:
The feed device performs preliminary grouping and positioning of pins before they reach the transfer location. Pins are arranged in groups and positioned at correct radial locations in advance, so that when individual twisting occurs, the pins are already near their final positions, minimizing additional handling and maintaining assembly efficiency.
Solution Approach 2:
The system maintains continuous operation by combining individual twisting with continuous pin feeding from the feed device. Rather than stopping to twist each pin separately, the feed device continuously supplies pins that are individually twisted in sequence, and the transfer device continuously transfers them to the wound part body, ensuring uninterrupted production flow.
3Ease of operation
If pins are positioned by radial displacement between a large and small diameter tool, then transfer is facilitated, but the method becomes inapplicable for certain winding configurations with nested pins or multiple layers
Solution Approach 1:
The patent transitions from radial positioning (single dimension) to a combination of radial and axial positioning (multiple dimensions). The feed device positions pins in groups at different radial locations, and the transfer device can adjust axial positions to accommodate nested pins and multiple layers, enabling the system to handle complex winding configurations that radial displacement alone cannot manage.
Solution Approach 2:
The transfer device incorporates adjustable and movable elements that can adapt their position and configuration based on the specific winding requirements. This dynamic capability allows the same device to handle various winding configurations including nested pins and multiple layers, rather than requiring fixed geometric constraints.
4Ease of operation
If a clamp is used to transfer pins from a large diameter tool to the wound part body, then transfer is achieved, but assembly time increases and manufacturing cost increases
Solution Approach 1:
The feed device automatically performs the grouping and preliminary positioning of pins without requiring external clamping tools or manual intervention. The system is self-sufficient in preparing pins for transfer, eliminating the need for additional transfer tools and reducing assembly time by integrating the preparation and transfer functions into a single automated sequence.
Data Source
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AI summary
The invention proposes a method for assembling conducting hairpin windings in a transfer device, the transfer device (40) comprising a spindle body (41) and a plurality of guide strips (42), lateral spaces (43) intended to house at least one conducting segment being defined between two adjacent guide strips. The method (120) comprises at least a step (121) of placing at least one group of hairpin windings (36) in a feed device (50); a plurality of feed steps (122), each feed step comprising transferring at least one group of hairpin windings (36) from the feed device (50) to a lateral space (43) of the transfer device (40); and a plurality of rotation steps (123), each rotation step separating at least two feed steps (122) from one another and comprising a movement of rotating the feed device (50) and/or the transfer device (40) so as to allow a next feed step.