Interlocking Stator End-Turn Tool for Precise Terminal Alignment
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Solution Overview
Problem
The existing multi-component tools for shaping stator winding end turns in electric machines are labor-intensive and costly due to the need for precise alignment and connection of multiple components, requiring specialized expertise and tooling.
Innovation Solution
An interlocking tool comprising two rotatable members with radially extending rings and comb fingers that are additively manufactured, allowing for simultaneous formation and alignment of stator end turns without the need for separate joining and alignment of multiple components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a multi-component tool with multiple coaxial rings is used to shape end turns, then the end turns can be properly shaped and terminal ends aligned, but the tool requires precise positioning and connection of multiple components which increases labor intensity and cost
Solution Approach 1:
The patent combines multiple coaxial rings into a single integrated tool body that is additively manufactured as one piece. This merging of components eliminates the need for precise assembly and connection of multiple separate rings, while still maintaining the ability to shape multiple layers of windings and align terminal ends effectively.
Solution Approach 2:
The single integrated tool body incorporates multiple rings with different diameters that can simultaneously engage and shape different layers of windings. This multi-functional design allows one component to perform the work of multiple separate components, reducing assembly complexity while maintaining manufacturing precision.
2Manufacturing precision
If multiple rings are connected and aligned using special tooling and expertise, then proper positioning is achieved, but the process takes time and increases overall cost
Solution Approach 1:
By additive manufacturing the tool as a single integrated component, the patent eliminates the time-consuming processes of connecting and aligning multiple separate rings. The rings are permanently positioned during manufacturing, requiring no assembly time during tool usage.
Solution Approach 2:
The precise positioning of rings is performed during the additive manufacturing process itself, rather than during tool assembly. This preliminary action ensures accurate ring positioning is built into the tool structure from the beginning, eliminating the need for time-consuming adjustment and alignment procedures.
3Ease of manufacture
If traditional mechanical connection methods are used for multiple tool components, then components can be assembled, but shims and mechanical fasteners are required which add complexity
Solution Approach 1:
The patent eliminates the need for mechanical fasteners and shims by additive manufacturing the tool as a single integrated component. This merging removes all intermediate connection elements, simplifying the tool structure while maintaining ease of manufacture through the additive process.
Data Source
AI summary
An interlocking tool for a for forming stator end turns includes a first member including a first base having a first surface. A first ring extends from the first surface and a second ring extends from the first surface radially outwardly of the first ring. The second ring is spaced from the first ring by a first gap. A second member includes a second base having a first surface portion. A first ring element extends from the first surface portion and a second ring element extends from the first surface portion radially inwardly of the first ring element. The second ring element is spaced from the first ring element by a second gap. The second ring is positioned in the second gap, and the second ring element is positioned in the first gap. The first member is rotatable relative to the second member.