Rotary Coil Segment Assembly for Multilayer Motor Windings
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Solution Overview
Problem
Existing coil assembly methods for electrical rotating machines are inefficient and time-consuming, particularly when assembling multilayered coil segments, as they require complex slot insertion and rotation processes, limiting production efficiency.
Innovation Solution
A coil assembling apparatus with a segment arrangement body featuring annularly arranged hold portions and a guide mechanism that allows coil segments to be inserted radially and rotated to guide slot insertion portions into place, enabling efficient and quick assembly of both single and multilayered coils by rotating the segment arrangement body at predetermined angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If coil segments are inserted one by one into slots manually, then assembly precision can be maintained, but production efficiency deteriorates significantly
Solution Approach 1:
The coil assembly is segmented into multiple coil segments that are pre-formed and then assembled together. Each coil segment can be independently manufactured and then systematically inserted into slots through the alignment device, combining precision with efficiency
Solution Approach 2:
Coil segments are pre-formed and pre-positioned in the alignment device before final assembly. The alignment device pre-arranges multiple coil segments in the correct sequence and orientation, so that when they are drawn out and inserted into slots, both precision and speed are maintained
2Productivity
If multiple coil segments are pre-arranged in an alignment device and then drawn out for insertion, then production efficiency improves, but assembly complexity increases
Solution Approach 1:
The alignment device uses a cylindrical arrangement with radially inclined slots, creating a circular/patterned structure that naturally guides coil segments into proper alignment. This curved geometry simplifies the positioning mechanism while maintaining assembly precision
Solution Approach 2:
The alignment device serves multiple functions: it stores coil segments, pre-aligns them in correct sequence and orientation, and facilitates their systematic extraction for insertion. This multi-functionality reduces the need for separate positioning mechanisms, simplifying overall assembly complexity
3Stability of the object's composition
If slot insertion portions are shifted and rotated to form multilayered segment assembly, then coil structure completeness improves, but assembly time increases
Solution Approach 1:
The alignment device pre-arranges coil segments in the correct configuration for multilayered assembly. The radially inclined slots are positioned to automatically guide segments into proper layers and orientations, pre-performing the shifting and rotation operations that would otherwise be time-consuming
Solution Approach 2:
The alignment device utilizes radial and axial dimensions to organize coil segments into multilayered structures. By arranging segments radially in the alignment device and extracting them in sequence, the system naturally forms multilayered coil assemblies without requiring complex post-assembly manipulation
Data Source
Figure 1(a)~1(b)
Figure 2A
Figure 2B
AI summary
Provided are a coil assembling apparatus, a coil assembling method and a manufacturing apparatus of the electrical rotating machine, whereby it is possible to efficiently and quickly assemble a coil consisting of a plurality of coil segments, and to easily and quickly assemble a coil consisting of a multilayered coil segments. The coil assembling apparatus includes a transport means for transporting in sequence a plurality of coil segments, each of the plurality of coil segments consisting of a pair of slot insertion portions extending substantially in parallel with each other and a linking portion for coupling the pair of slot insertion portions, a segment arrangement body capable of rotating around a center axis thereof and provided with a plurality of segment hold portions annularly arranged along a circumferential direction of the segment arrangement body, into which the plurality of coil segments transported by the transport means can be respectively inserted from an outer radial directions of the segment arrangement body, and a guide means for guiding to insert one slot insertion portion of the pair of slot insertion portions of each of the coil segments into one of the segment hold portions each time the segment arrangement body rotates by a first predetermined angle, and for guiding to insert the other one slot insertion portion of the pair of slot insertion portions into the other one of the segment hold portions when the segment arrangement body rotates by a second predetermined angle from the insertion of the one slot insertion portion.