Segment Coil Armature Manufacturing Without Insulation Damage

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Solution Overview

Problem

Existing methods of manufacturing armatures risk damaging insulating films at the final ends of segment coil leg portions during the widening of interlayer intervals.

Innovation Solution

A method involving a tool with tilted teeth, moved by a robot manipulator, is used to insert between the final ends of segment coil layers without contacting the insulating films, thereby preventing damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a disentangling member is moved in the radial direction and axial direction to widen interlayer intervals, then the complexity of aligning final ends is reduced and work efficiency is improved, but the insulating films at the final ends may be damaged due to sliding contact

Engineering Contradiction:

Improvework efficiency in twisting stepVSAvoiddamage to insulating films

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an air cushion as an intermediary between the disentangling member and the insulating films. By blowing air from nozzles positioned near the final ends, an air layer is formed that prevents direct contact between the disentangling member and the insulating films, thereby protecting them while still allowing the disentangling operation to proceed efficiently

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent employs pneumatic means by using air nozzles to generate an air cushion. Compressed air is supplied through nozzles positioned in the vicinity of the final ends of segment coil leg portions, creating a pneumatic barrier that prevents mechanical contact and potential damage to the insulating films during the disentangling process

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Ease of operation

If the disentangling member contacts the final ends to widen intervals, then the alignment complexity is reduced, but the insulating films are damaged

Engineering Contradiction:

Improvealignment of final endsVSAvoidintegrity of insulating films

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The air cushion acts as a mediator that allows the disentangling member to approach and separate the final ends without making direct contact with the insulating films. This maintains the ease of operation for alignment while preserving the reliability of the insulating film integrity

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The air cushion is established beforehand before the disentangling member makes contact with the final ends. By pre-forming the protective air layer through the nozzles, the insulating films are cushioned against potential damage while still allowing the disentangling operation to proceed

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS20250239925A1Method of manufacturing armature

Publication Date: 2025.07.24 NHK SPRING CO LTD

AI summary

With this manufacturing method, a stator provided with a plurality of segment coils, both leg portions of which are inserted into each slot of a stator core and which are overlapped in the radial direction of the stator core into a plurality of layers and aligned in an annular shape, is manufactured. In this manufacturing method, a tool having teeth is moved by a robot manipulator and thereby the teeth are inserted between the terminals of the leg portions of the respective layers. When inserted, the tool is tilted in the insertion direction of the teeth and around the axis orthogonal to the radial direction and thereby the ends of the teeth are made non-contact with the insulating coatings of the terminals of the leg portions.