Interchangeable Cylindrical Jig for Variable Diameter Coil Alignment
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Solution Overview
Problem
Existing aligning apparatuses for forming aligned coils are limited in versatility, requiring multiple machines to produce coils of different diameters for various stators, leading to increased manufacturing costs and inefficiency.
Innovation Solution
An aligning apparatus comprising a cylindrical jig and a hook jig, where the hook jig remains common and the cylindrical jig is interchangeable, allowing the formation of aligned coils of various diameters using a single machine, by rotating the cylindrical and hook jigs relative to each other to align U-shaped coil segments in an annular configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple dedicated aligning machines are used to produce coils of different diameters, then manufacturing precision for various stator sizes is ensured, but manufacturing cost increases and production efficiency decreases
Solution Approach 1:
The aligning machine is designed with interchangeable cylindrical jigs that can be swapped to accommodate different coil diameters. The hook jig remains common while the cylindrical jig changes, allowing one machine to perform multiple functions for producing aligned coils of various diameters, thus resolving the contradiction between precision and adaptability
Solution Approach 2:
The aligning machine is divided into separable components: a common hook jig and interchangeable cylindrical jigs. This segmentation allows the cylindrical jig to be changed according to the required coil diameter while retaining the universal hook jig, enabling precision maintenance across different production scenarios
2Manufacturing precision
If multiple dedicated aligning machines are used for different coil diameters, then manufacturing precision is maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
By designing a universal hook jig that works with multiple cylindrical jigs, the system reduces the total number of machines needed. This decreases device complexity and manufacturing cost while maintaining alignment precision through the standardized hook jig design
Solution Approach 2:
The common hook jig is merged with multiple interchangeable cylindrical jigs to create a family of tooling sets that can be used on a single machine. This merging approach consolidates multiple dedicated machines into one versatile unit, reducing overall system complexity
3Manufacturing precision
If multiple dedicated aligning machines are used, then manufacturing precision for various stator sizes is ensured, but productivity decreases due to underutilization of equipment
Solution Approach 1:
The interchangeable cylindrical jig system allows a single aligning machine to produce aligned coils for multiple stator sizes sequentially. This eliminates equipment underutilization and increases productivity while maintaining precision through the standardized alignment mechanism
Solution Approach 2:
The system introduces dynamic reconfigurability through interchangeable jigs, allowing the machine to adapt its configuration based on production requirements. This dynamic capability enables continuous utilization of the same equipment for different products, improving overall productivity
Data Source
AI summary
An aligning apparatus, which is provided for aligning coil segments to form an aligned coil, includes a cylindrical jig and a hook jig. The cylindrical jig has an outer cylinder to surround a radially outer periphery of the aligned coil and an inner cylinder to be surrounded by a radially inner periphery of the aligned coil. The hook jig has hooks arranged in a radial fashion and is rotatable relative to the cylindrical jig in a radial direction. The cylindrical jig further has an inner entrance provided in the inner cylinder, an outer entrance provided in the outer cylinder, and at least one of an inner guide wall extending from a front opening edge of the inner entrance radially inward and backward in the rotational direction and an outer guide wall extending from a front opening edge of the outer entrance radially outward and backward in the rotational direction.