Mandrel with Stepped Radii for Stator Segment Assembly
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Solution Overview
Problem
The production of stator segments for electrical machines using dovetails increases production costs and requires high dimensional accuracy, while also limiting the possibility of assembly in smaller machines due to space constraints, and existing solutions like pressing segments into housings are disadvantageous in terms of weight and installation space.
Innovation Solution
A device with a mandrel having three differently designed regions for receiving and aligning stator segments, allowing for efficient assembly and calibration, featuring a segment feed, press, and housing feed, with movable mandrel arms and electromagnets for precise alignment and prevention of overpressing, enabling quick and space-saving assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dovetails are incorporated into stator segments for firm connection, then the stator segments achieve form-locking connection and adequate dimensional accuracy, but the production cost increases and the dimensional accuracy demands on stator sheets increase
Solution Approach 1:
The patent extracts the form-locking connection function from the dovetail structure and transfers it to the housing structure. Instead of incorporating dovetails into the stator segments, the housing is designed with a form-locking structure that receives the cylindrical stator segments, achieving the same connection purpose without modifying the segments themselves, thereby reducing production cost and dimensional accuracy demands on the segments.
Solution Approach 2:
The patent inverts the traditional approach by not forming dovetails on the stator segments, but rather creating the form-locking connection through the housing structure. The housing receives the cylindrical segments and provides the locking mechanism, reversing who provides the connection feature - the segments remain simple cylinders while the housing provides the complex form-locking geometry.
2Manufacturing precision
If dovetails are incorporated into stator segments for form-locking connection, then adequate dimensional accuracy is achieved, but the possibility of inserting dovetails into stator segments of smaller electrical machines diminishes due to limited space
Solution Approach 1:
The patent extracts the form-locking connection feature from the stator segments and relocates it to the housing. This allows the stator segments to remain as simple cylindrical structures that can be easily adapted to different machine sizes, while the housing provides the form-locking connection regardless of the specific application scale.
Solution Approach 2:
The patent creates a universal solution where the cylindrical stator segments can be used across different machine sizes and applications. The form-locking connection is provided by the housing rather than the segments, making the segments universally adaptable while the housing is customized for specific machine requirements including size constraints.
3Weight of stationary object
If stator segments are pressed directly into the housing without form fit, then weight and installation space are reduced, but the segments require complex holding between pressing and insertion into the housing
Solution Approach 1:
The patent applies preliminary action by providing the form-locking structure in advance within the housing design. The housing is pre-configured with the form-locking geometry that will engage with the stator segments during pressing, eliminating the need for complex temporary holding mechanisms. The segments are simply pressed into the pre-prepared form-locking receptacles in the housing.
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
Enables quick, safe, and precise assembly of stator segments in a small space, allowing for flexible adaptation to different stator sizes by using the mandrel as a tool and means of transport, reducing production costs and improving dimensional accuracy.
Implementation Method 1
The mandrel has an electromagnet for holding the stator segment
Data Source
AI summary
A device for producing a stator for an electrical machine includes a segment feed for feeding stator segments, a cylindrical press for pressing the stator segments, a housing feed for feeding stator housings, and a mandrel for receiving the stator segments. The mandrel includes an axial direction, a first region with a first radius, a second region arranged axially below the first region with a second radius that is less than the first radius, and a third region arranged axially below the second region with a third radius that is less than the second radius. In an example embodiment, the mandrel is movable from the segment feed to the cylindrical press, from the cylindrical press to the housing feed, and from the housing feed to the segment feed.