Self-fixturing Jumper Bridge for Hairpin Winding Stator Assembly
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Solution Overview
Problem
The existing manufacturing processes for stator assemblies in electric machines require intricate and expensive fixturing to properly position and weld jumper bridges, neutral bridges, and terminal lugs, increasing cycle time and cost due to the complex geometries and high number of welds involved.
Innovation Solution
A unitary jumper with spaced-apart C-hooks is used, which slides onto and is seated by ledges defined by insulative coatings on hairpin winding terminals, eliminating the need for fixturing by forming a bridge that spans between same-phase terminals and over different-phase terminals, allowing for bonding without additional support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If intricate fixturing is used to hold jumper bridges and terminal lugs in proper positions, then positioning accuracy is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The jumper bridge is designed with self-positioning features including engagement protrusions that fit into recesses on the stator core, and engagement tabs that snap into grooves on terminal lugs. This self-service mechanism eliminates the need for external fixturing to maintain positioning accuracy during assembly.
Solution Approach 2:
The jumper bridge is divided into multiple functional segments: a bridge portion spanning between terminals, engagement protrusions for stator core attachment, and engagement tabs for terminal lug connection. This segmentation allows each feature to independently perform its positioning function without requiring complex overall fixturing.
2Manufacturing precision
If intricate fixturing is used to position multiple circuit components, then positioning accuracy is improved, but manufacturing cycle time increases
Solution Approach 1:
The jumper bridge is pre-formed with all positioning features (engagement protrusions, tabs, and recesses) already in place before assembly. This preliminary preparation eliminates the need for time-consuming adjustments and fixturing setup during the actual assembly process, reducing manufacturing cycle time while maintaining positioning accuracy.
3Ease of manufacture
If traditional stamping and fixturing processes are used for jumper bridges, then manufacturing capability is achieved, but manufacturing cost increases
Solution Approach 1:
Multiple functions are merged into a single jumper bridge component: electrical connection between terminals, mechanical support structure, and self-positioning mechanism. This consolidation eliminates the need for separate fixturing components while maintaining manufacturing capability through standard stamping processes.
Solution Approach 2:
The jumper bridge incorporates self-positioning engagement features that automatically align and secure the component during assembly without requiring external fixturing. This self-service capability simplifies the manufacturing process and reduces overall system complexity while maintaining ease of manufacture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This simplifies the manufacturing process by reducing the need for fixturing, lowering production time and cost, while ensuring accurate positioning and enhanced electrical continuity through a larger contact area between the jumper and terminals.
Implementation Method 1
The C-hooks abut against and are axially positioned relative to the first-phase terminals by ledges defined by insulative coatings that cover the axially-lower portions of the first-phase hairpin winding terminals
Implementation Method 2
The C-hooks are then bonded (by welding, for example) with the respective exposed ends of the respective terminals
Data Source
AI summary
A stator of an electric machine has first and second hairpin winding terminals connected with a first electrical phase and extending axially away from end windings of the stator. A hairpin winding of a second electrical phase is located circumferentially between the first-phase terminals and spaces them from one another. A jumper has spaced-apart C-hooks oriented face-to-face relative to one another and wrapping around respective exposed ends of the first-phase hairpin winding terminals. The jumper forms a bridge spanning between the first-phase hairpin winding terminals and over the second-phase hairpin winding terminal. During manufacturing of the stator, the C-hooks are slid axially downward onto respective non-insulated ends of the first-phase stator hairpin winding terminals. The C-hooks abut against and are axially positioned relative to the first-phase terminals by ledges defined by insulative coatings that cover portions of the first-phase hairpin winding terminals.