Laser Insulation Stripping for Aligned Stator Coil Ends
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Solution Overview
Problem
The existing method for removing insulating films from conductor wire coil pieces requires individual handling and processing, leading to reduced productivity due to the need for conveying coil pieces in and out of a laser separator one at a time.
Innovation Solution
A method where coil pieces are aligned such that their extremities are adjacent to each other, allowing for continuous application of a film removing laser to efficiently strip the insulating film from multiple coil pieces simultaneously within a laser separator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If coil pieces are conveyed and processed individually in a laser separator, then the insulating film can be removed from each coil piece, but productivity is reduced due to sequential processing
Solution Approach 1:
Multiple coil pieces are merged into a single processed unit by aligning them in a bundle with their extremities facing the laser separator. This allows the laser separator to process multiple coil pieces simultaneously in one operation, converting sequential individual processing into parallel batch processing, thereby significantly improving productivity without requiring multiple laser separators
Solution Approach 2:
The coil pieces are arranged in a bundled configuration where multiple pieces occupy different spatial positions within the same processing zone. This dimensional arrangement allows the laser separator to apply laser light to multiple coil pieces at once through the bundle structure, transforming the processing from a one-dimensional sequential approach to a multi-dimensional simultaneous approach
2Productivity
If coil pieces are aligned with extremities adjacent to each other for simultaneous laser processing, then productivity increases, but precise alignment is required
Solution Approach 1:
The coil pieces are pre-aligned in a bundled configuration before entering the laser separator. This preliminary alignment action ensures that the extremities of all coil pieces are properly positioned adjacent to each other, creating the necessary conditions for simultaneous laser processing. The alignment is established in advance, allowing the laser separator to focus on the removal operation without requiring complex real-time adjustment mechanisms
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly increases productivity by enabling efficient removal of insulating films from multiple coil pieces in a single operation, improving the efficiency of the process compared to individual handling.
Implementation Method 1
applying laser light to an insulating film on a rectangular conductor wire so as to separate the insulating film therefrom
Implementation Method 2
continuously applying film removing laser to the extremities of the aligned coil pieces such that the laser is applied to one extremity and then to another extremity, thus removing at least portions of the insulating film
Data Source
AI summary
A conductor wire insulating film separating method disclosed includes: a preparing step involving preparing rectangular cross-section coil pieces each of which is a conductor wire coated with insulating film and used to provide a stator coil of rotary electric machine; a delivering-in step involving, after the preparing step, delivering coil pieces into a laser separator, with coil pieces aligned such that extremities thereof are adjacent to each other; an applying step involving, after the delivering-in step, continuously applying film removing laser to the extremities of the aligned coil pieces such that the laser is applied to one extremity and then to another extremity, thus removing at least portions of the insulating film from the extremities of the coil pieces; and a delivering-out step involving delivering the coil pieces, from which the at least portions of the insulating film have been removed by the applying step, out of the laser separator.