Segment Coil Alignment Jig for Multi-Layer Annular Assembly
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Solution Overview
Problem
Conventional coil segment annular alignment devices require separate jigs and additional mechanisms to form coil assemblies with three or more layers, leading to increased equipment costs, device size, and reduced production efficiency.
Innovation Solution
A coil alignment device and method using a plate-shaped first jig with grooves and a second jig that allows for the alignment of segment coils in an annular shape, enabling the formation of a coil aligned unit with a desired number of layers using the same device, reducing costs and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate jigs and additional mechanisms are prepared for forming coil assemblies with three or more layers, then the coil assembly can be formed with desired number of layers, but equipment cost increases and device size increases
Solution Approach 1:
The alignment annular portion is designed with multiple storage holes arranged at different radial distances from the center, allowing a single jig to accommodate and align segment coils for forming coil assemblies with different numbers of layers (2, 3, 4, or more layers). This eliminates the need for separate jigs for different layer configurations.
Solution Approach 2:
The alignment annular portion is divided into multiple independent storage holes, each capable of holding segment coils for different layers. This segmentation allows flexible configuration of coil layers within a single jig structure, enabling the formation of multi-layer coil assemblies without additional mechanisms.
2Manufacturing precision
If separate jigs and additional mechanisms are prepared for forming coil assemblies with three or more layers, then the coil assembly can be formed with desired number of layers, but production efficiency deteriorates
Solution Approach 1:
The alignment annular portion serves multiple functions by accommodating segment coils for different layer configurations simultaneously. Operators can form coil assemblies with 2, 3, 4, or more layers using the same jig, reducing the number of processing steps and improving production efficiency.
Solution Approach 2:
Multiple storage holes are pre-configured at different radial positions to receive segment coils for different layers. This preliminary arrangement allows operators to efficiently assemble multi-layer coil assemblies in a single operation without requiring additional mechanisms or multiple processing steps.
3Adaptability or versatility
If the storage hole length is increased to accommodate more leg portions for additional layers, then coil assemblies with more layers can be formed, but the device size increases
Solution Approach 1:
Instead of increasing the length of storage holes in one dimension, the solution adds multiple storage holes at different radial distances from the center in a two-dimensional radial arrangement. This allows the formation of coil assemblies with different numbers of layers without increasing the overall device size.
Solution Approach 2:
The storage space is segmented into multiple independent holes positioned at different radial distances. Each hole can accommodate segment coils for specific layers, allowing flexible formation of 2, 3, 4, or more layer coil assemblies within a compact jig structure.
Data Source
AI summary
A coil alignment device includes: a plate-shaped first jig having a plurality of grooves arranged along a circumferential direction so as to extend toward a radial-direction outer side; and a second jig that can contact with a segment coil inserted in the first jig. Each groove includes a storage portion extending along a radial direction and having a first length so that leg portions of the segment coils can be stored side by side in the radial direction, and a guiding portion extending from the storage portion toward the radial-direction outer side, and has a first shape so that, using, as a fulcrum, one leg portion inserted in the storage portion, the other leg portion is movable toward the storage portion. The second jig is movable to press the segment coil from a radial-direction side and store the other leg portion into the storage portion.