Radial Wire Insertion Device for Electric Motor Stators
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Solution Overview
Problem
The increasing demand for electric motor components, such as stators and rotors, requires more efficient production methods for inserting wires into grooves, as existing methods are not adequately fast or efficient for large-scale manufacturing, particularly in the context of electric vehicle applications.
Innovation Solution
A method and device utilizing radially offset wires, with first and second gripping elements to compress and radially move the wires into grooves, allowing for efficient alignment and insertion, which can include the use of a radial engine and guide plates to facilitate the process, and optionally using a hybrid approach combining gripping elements and radial engine for compression and insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional wire insertion methods are used, then the production process is simpler, but the insertion speed and efficiency are insufficient for large-scale manufacturing
Solution Approach 1:
The insertion device is segmented into multiple independent gripping elements (first gripping elements and second gripping elements) that can operate simultaneously on multiple wires. Each gripping element functions as an independent unit, allowing parallel processing of multiple wires to increase overall insertion speed while maintaining manageable complexity through modular design
Solution Approach 2:
The patent introduces a radial dimension to the wire insertion process by providing wires radially offset to the component and using radially movable gripping elements. This dimensional change allows wires to be approached and inserted from the radial direction rather than only from the axial direction, enabling new insertion pathways and improving access to grooves in the component
2Ease of manufacture
If wires are inserted without compression, then the insertion process is faster, but wires may not fit properly into grooves and production efficiency decreases
Solution Approach 1:
The gripping elements perform preliminary compression of the wires before insertion into the grooves. By compressing the wires in advance while they are still accessible from the radial direction, the wires are pre-formed to fit the groove geometry, eliminating the need for time-consuming adjustments during the insertion process itself and actually reducing total cycle time
3Manufacturing precision
If multiple gripping elements are used to compress and insert wires, then insertion precision and wire protection are improved, but the device complexity increases
Solution Approach 1:
The gripping elements are designed with multi-functionality, serving both as compression devices and as insertion tools. The same first gripping elements that compress the wires also guide and insert them into the grooves, eliminating the need for separate compression devices and insertion tools, thereby reducing overall device complexity while maintaining precision
Solution Approach 2:
The patent merges the compression function and insertion function into a single integrated gripping element system. The first gripping elements and second gripping elements work together as a unified mechanism that simultaneously compresses and inserts wires, reducing the number of separate components needed and simplifying the overall device structure
Data Source
AI summary
A method and to a device for inserting a plurality of wires into a plurality of grooves of a component, such as a stator or rotor of an electric motor, in which the wires are inserted by gripping elements.