Motor Armature Bending with Nonlinear Profiles
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Solution Overview
Problem
Existing methods for fabricating motor armatures with laminated conductors often result in inadequate alignment and excessive bending stresses due to linear bending profiles, which are insufficient for modern motors with improved materials and increased mechanical power requirements.
Innovation Solution
The use of computer numerically controlled machines with fixtures actuatable in orthogonal directions, guided by software to implement nonlinear bending profiles that relate incremental translation to rotational movement, ensuring proper alignment and managing bending stresses by varying the axial compression in a monotonically increasing manner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a linear bending profile is used with fixed axial compression for each incremental rotational movement, then the manufacturing process is simple and easy to control, but the alignment of slot conductors with commuter conductors is inadequate and bending stresses are excessive
Solution Approach 1:
The patent applies parameter changes by transitioning from a linear bending profile with fixed axial compression to a nonlinear bending profile where axial compression varies as a function of rotational position. This allows the bending process to adapt to the changing geometric requirements as the armature rotates, achieving proper conductor alignment while managing bending stresses through dynamically adjusted compression parameters.
Solution Approach 2:
The patent implements dynamics by making the bending profile adaptive rather than static. The axial compression amount is dynamically adjusted based on the rotational position and the specific geometric relationships between slots and commuter conductors. This dynamic control enables the system to handle the varying alignment requirements throughout the bending process, resolving the contradiction between precision and complexity.
2Strength
If a linear bending profile with fixed axial compression is applied, then the fabrication process is straightforward, but the bending stresses in slot conductors are excessive and alignment is inadequate
Solution Approach 1:
The patent changes the compression parameter from a fixed value to a variable that depends on rotational position and conductor geometry. By adjusting the axial compression amount dynamically during the bending process, the system optimizes stress distribution in the slot conductors, preventing excessive bending stresses while maintaining manufacturing feasibility through computer-controlled adjustment.
3Power
If modern materials with higher mechanical power capabilities are used, then the motor performance is improved, but the existing linear bending profiles become inadequate for achieving proper alignment and managing stresses
Solution Approach 1:
The patent adapts the bending process parameters to match the improved material properties and higher power requirements. By implementing nonlinear bending profiles with variable axial compression, the system achieves the precise alignment and stress management needed for modern high-performance materials, enabling these advanced materials to realize their full potential in smaller, higher-power motor designs.
Data Source
AI summary
A method of fabricating an armature for a motor includes providing a laminated assembly having a length, a central axis, and a plurality of open slots each extending the length and each configured to locate one conductor at a first greater radial distance from the central axis and another conductor at a second lesser radial distance from the central axis. A first conductor is inserted into a first one of the slots at the greater radial distance such that the first conductor extends out of the first one of the slots. A free end of the inserted first conductor is bent in each of a first direction and a second direction orthogonal to the first direction. A second conductor is inserted into a second one of the slots at the lesser radial distance such that the second conductor extends out of the second one of the slots. A free end of the inserted second conductor is bent in each of the two orthogonal directions.