Rim Arranging Device for Stator Conductor Insertion
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Solution Overview
Problem
Existing methods for forming and inserting rim arrangements of electrical conductors into electrical machine components, such as stators, require multiple stations and complex nesting processes, leading to increased apparatus and process technology outlay.
Innovation Solution
A rim arranging and joining device with a collecting receptacle, radially movable ribs, and a positioning system that allows for the axial insertion of concentrically arranged U-shaped conductors into a component, reducing the need for pre-fixed nests and enabling direct insertion into the stator housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple pre-fixed nests and multiple stations are used for forming and inserting rim arrangements, then conductor positioning precision is improved, but device complexity and apparatus outlay increase
Solution Approach 1:
The patent combines multiple pre-fixed nests into a single collecting receptacle with radially movable ribs that can dynamically form groove structures. The ribs can be positioned radially outward to create grooves for conductor placement, then moved radially inward to release the conductors for insertion into the stator, eliminating the need for multiple separate nesting stations while maintaining positioning precision.
Solution Approach 2:
The collecting receptacle employs radially movable ribs that can dynamically change their radial position between an outer position (for forming and positioning grooves) and an inner position (for releasing conductors). This dynamic adjustment allows the same structure to serve multiple functions: precise positioning during formation and easy release during insertion, replacing multiple static nesting devices.
2Manufacturing precision
If multiple stations and complex nesting processes are used, then conductor arrangement precision is improved, but manufacturing cycle time increases
Solution Approach 1:
The patent merges multiple nesting and positioning stations into a single integrated collecting receptacle that performs all conductor formation, positioning, and release operations. This consolidation eliminates the need to transfer conductors between multiple stations, reducing cycle time while maintaining the precision required for proper conductor arrangement in the stator.
Solution Approach 2:
The radially movable ribs perform preliminary positioning actions by forming grooves in the collecting receptacle where conductors are placed and positioned with high precision. Once positioning is complete, the ribs are moved radially inward to release the conductors, preparing them for immediate insertion into the stator without requiring additional positioning stations or operations.
3Manufacturing precision
If separate pre-mounting nests and collecting nests are used, then conductor positioning accuracy is improved, but the number of apparatus components increases
Solution Approach 1:
The patent combines separate pre-mounting nests and collecting nests into a single collecting receptacle structure. The radially movable ribs can be positioned radially outward to form grooves that serve as pre-mounting positions, then moved radially inward to transfer the conductors to the insertion position, eliminating the need for multiple separate nesting devices while maintaining positioning accuracy throughout the process.
4Ease of operation
If radially movable ribs are used for forming and releasing rim arrangements, then ease of insertion is improved, but device complexity increases
Solution Approach 1:
The radially movable ribs provide a simple yet effective mechanism for both forming the rim arrangement structure and releasing it for insertion. By moving the ribs radially outward, grooves are formed to hold conductors in precise positions; by moving them radially inward, the conductors are automatically released and ready for insertion into the stator. This single dynamic mechanism replaces complex multi-component nesting and release systems.
Data Source
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AI summary
To simplify the arrangement of rings into a ring assembly and the joining of the ring assembly into a component chamber, such as in particular a stator of an electric machine, the invention provides a ring assembly and joining device (10) for forming and inserting a ring assembly (82) from at least one ring or several concentrically arranged rings (14a-14c) of preferably U-shaped electrical conductors into a component of an electric machine, comprising a collective receptacle (12) with several grooves (24) arranged annularly around an axis and bounded by radial webs (38), a web movement device (92) for radially moving the webs (38), a component positioning device (94) for positioning the component in a position aligned with the collective receptacle (12), and a ring assembly joining device (96) for axially inserting the ring assembly (82) with the webs (38) retracted from the collective receptacle (12) into the component.