Segmented Coil Segment Positioning Tool for Stator Core Alignment
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Solution Overview
Problem
Existing coil segment positioning methods face challenges with inaccurate alignment and mechanical strength due to large openings in positioning plates, leading to complex and troublesome operations, especially when correcting positional deviations in the radial direction of the core.
Innovation Solution
A coil segment positioning method using a tool with separate insertion holes for each distal end pair, allowing for rough positional adjustment and improved alignment, enhancing working efficiency and mechanical strength by reducing the ratio of openings to plate area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a positioning plate with large openings (insertion windows) is used to accept multiple segment end pairs, then the ease of insertion is improved, but the manufacturing precision and alignment accuracy deteriorate
Solution Approach 1:
The patent divides the positioning system into multiple separate positioning plates, each responsible for positioning a specific segment end pair. This segmentation allows each plate to have precise positioning features (protrusions and recesses) that ensure accurate alignment, while still maintaining ease of insertion through dedicated insertion windows. The modular approach resolves the contradiction by providing both precision and ease of operation at the component level.
2Ease of operation
If the ratio of openings to plate area is increased to facilitate insertion, then the ease of operation is improved, but the mechanical strength of the positioning plate deteriorates
Solution Approach 1:
By segmenting the positioning system into multiple smaller plates rather than using one large plate with large openings, the patent maintains adequate mechanical strength in each individual plate while still providing sufficient opening area for easy insertion. Each smaller plate requires less material to maintain structural integrity, yet the collective system provides the necessary access for all segment end pairs.
3Manufacturing precision
If complex positioning operations are performed to correct radial misalignment, then the manufacturing precision is improved, but the productivity and working efficiency deteriorate
Solution Approach 1:
The patent incorporates preliminary positioning features (protrusions and recesses) into the positioning plates that pre-align the segment end pairs in the radial direction before the actual positioning operation. This preliminary action eliminates the need for complex corrective operations during the main positioning process, thereby maintaining high positioning accuracy while significantly improving working efficiency and productivity.
Data Source
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AI summary
A weld end positioning apparatus (2) that is an example of a positioning apparatus has a base member (10) configured to support a stator core (18), a positioning tool (4) disposed on its upper surface, and a driving mechanism (16) for driving it. The positioning tool (4) has a first plate (6) and a second plate (8). The first plate (6) has an inner side ring (32) and an annular plate body (36) fixed to the upper surface thereof, and the second plate (8) has an outer side ring (38) and a plate body (42) fixed to the upper surface thereof. Insertion holes (62, 62') each configured to accept insertion of one of distal end pairs (22) are formed on the plate body (36) and the plate body (42), respectively, and positioning is performed by rotating these plate bodies (36,42) in opposite directions. Positions of the distal end pairs (22) are aligned in the radial direction without the positioning tool (4), and then the positioning tool (4) is set.