Segment Coil Jig Alignment for Accurate Armature Assembly
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Solution Overview
Problem
Existing armature manufacturing processes face complications in assembly and insertion of segment coils due to low positional accuracy, leading to defective products and reduced efficiency.
Innovation Solution
An armature manufacturing device with a segment coil jig and chuck that enhance positional accuracy by engaging leg tips of segment coils from the radial direction and include variable mechanisms for gripping and aligning coils in a circular ring shape, facilitating easier assembly and insertion into slots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If segment coils are aligned without a radial direction engagement section, then the device structure is simpler, but positional accuracy between segment coils is low
Solution Approach 1:
The radial direction engagement section acts as an intermediary component between the segment coils and the jig. It provides a dedicated interface for radial positioning, enabling precise alignment without requiring complex overall jig structure. The engagement section translates radial forces into precise positional constraints.
2Productivity
If multiple segment coils are assembled manually, then the assembly process is more flexible, but production efficiency is reduced
Solution Approach 1:
The segment coil jig combines multiple functions into a single integrated device: alignment of individual coils, stacking in radial direction, circumferential alignment in circular ring shape, and gripping interface. This merging eliminates multiple separate operations and enables automated high-speed assembly.
Solution Approach 2:
The jig is divided into distinct functional sections: the upper section with jig slots for individual coil insertion, the lower section with radial engagement sections for stacking, and the gripping interface. This segmentation allows each section to perform its specific function efficiently while working together as a unified system.
3Ease of manufacture
If segment coils are aligned with high positional accuracy, then assembly and insertion become easier, but the alignment device becomes more complex
Solution Approach 1:
The invention adds radial direction positioning capability to the traditional alignment system. By introducing engagement sections that operate in the radial dimension, the device achieves precise positioning in three dimensions (axial, radial, circumferential) without requiring overly complex mechanisms in any single dimension.
Data Source
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AI summary
To improve efficiency of armature manufacture. An assembly jig (40), which is a segment coil jig configured to stacking plural segment coils (20) into a multilayer form and aligning them into a circular ring shape includes an upper section (42) formed with plural jig slots (44) for inserting the plural segment coils (20) into, and a lower section (48) that is abutted by leg tips of the plural segment coils (20) inserted into the plural jig slots (44). The lower section (48) includes a widening prevention part (52) and a closing prevention part (54) preventing the leg tips of the plural segment coils (20) from widening or closing from a radial direction outer side and a radial direction inner side thereof.