Rotary Table Winding Assembly for Precise Stator Insertion
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Solution Overview
Problem
Existing systems for assembling stator or rotor windings in electric machines face challenges with accuracy and efficiency due to complex and costly mechanisms, leading to high cycle times and potential misalignment of hairpin legs during insertion into the stator pack.
Innovation Solution
A system utilizing a rotary table with removable inserters and circular containments to assemble and insert windings, featuring a circular containment that sustains and aligns conductors for precise insertion, and a thrust assembly to guide the winding into the stator pack, allowing for simultaneous assembly and insertion with improved precision and reduced complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex mechanisms are used for assembling windings, then manufacturing precision is improved, but device complexity increases and productivity decreases
Solution Approach 1:
The patent employs circular containment structures that act as flexible guides to sustain and align conductors during insertion. These containments provide the necessary alignment precision through their circular geometry and containment walls, replacing complex mechanical alignment mechanisms while maintaining manufacturing precision for hairpin leg positioning.
Solution Approach 2:
The rotary table serves multiple functions: it holds the circular containment, enables rotational movement for insertion from different angles, and coordinates the assembly process. This multi-functional design consolidates what would otherwise require separate complex mechanisms, reducing device complexity while maintaining alignment accuracy through the integrated system.
2Manufacturing precision
If complex mechanisms are used for inserting windings, then manufacturing precision is improved, but productivity deteriorates due to high cycle times
Solution Approach 1:
The circular containment structure provides continuous guidance and support for conductors during insertion, ensuring precision without requiring complex mechanical guides. The containment walls maintain conductor alignment throughout the insertion process, achieving high insertion precision while enabling faster cycle times compared to traditional complex guiding mechanisms.
Solution Approach 2:
The rotary table enables dynamic insertion operations by allowing the circular containment to rotate and position conductors at optimal angles for insertion. This dynamic capability replaces static complex mechanisms, improving both insertion precision and productivity by enabling smoother, faster insertion operations with reduced cycle times.
3Device complexity
If traditional assembly methods are used, then device complexity is reduced, but manufacturing precision deteriorates due to misalignment of hairpin legs
Solution Approach 1:
The circular containment structure serves as a simple yet effective alignment mechanism, using its circular geometry and containment walls to guide conductors into precise positions. This approach achieves high manufacturing precision for hairpin leg alignment without requiring complex mechanical systems, maintaining simplicity while improving accuracy compared to traditional methods.
Solution Approach 2:
The invention changes the geometric parameters of the containment structure to circular form, which inherently provides superior alignment characteristics compared to traditional linear or angular guides. This parameter change enables precise hairpin leg alignment through the circular path and containment walls, achieving high manufacturing precision with a relatively simple device configuration.
4Manufacturing precision
If multiple separate mechanisms are used for assembly and insertion, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent merges the assembly and insertion functions into a single integrated system: the rotary table with circular containment combines conductor holding, alignment, and insertion capabilities in one mechanism. This consolidation maintains manufacturing precision by ensuring continuous guidance throughout the process while reducing device complexity by eliminating the need for separate assembly and insertion mechanisms.
Solution Approach 2:
The circular containment structure performs multiple functions simultaneously: it sustains conductors during assembly, aligns them for precise insertion, and guides them into the stator pack. This multi-functional design replaces what would otherwise require multiple separate mechanisms, reducing device complexity while maintaining high alignment and insertion accuracy through the unified system.
Data Source
AI summary
An assembly and insertion system for assembling and inserting, into a stator pack, a winding having one or more layers of basic conductors is provided. The assembly and insertion system has a circumferential containment of the basic conductors with a set of spaces or slots, and one or more removable inserters of the basic conductors into the circumferential containment, and elements for rotating the circumferential containment about the winding axis. A rotary table is configured to rotate about a table axis to bring the circumferential containment from an assembly position to an insertion position for insertion into the stator pack. The winding is assembled on one side of the rotary table while feeding elements of the stator pack and relative introduction elements of the winding into the stator pack at the insertion position act on the opposite side. A process for assembling and inserting a winding into a stator pack is also provided.