Sequential Coil-End Bending for Compact Stator Manufacturing
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Solution Overview
Problem
Conventional stator manufacturing methods require large and rigid devices for bending and molding coil ends due to simultaneous collective bending, limiting the reduction in stator diameter and increasing device size.
Innovation Solution
A method and device that utilize a single bending member to sequentially bend and mold coil ends by moving in a spiral manner, reducing the number of bending members needed and minimizing interference, allowing for a smaller device and reduced stator diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple molding jigs are used to simultaneously bend and mold all coil ends, then all coil ends are processed at the same time, but the molding load becomes excessively large and the device size increases
Solution Approach 1:
The patent divides the coil ends into multiple groups and processes them in sequence rather than simultaneously. The bending member processes a first group of coil ends, then moves to process a second group, and so on. This segmentation reduces the number of coil ends subjected to bending force at any one time, thereby reducing the molding load and allowing for a smaller, more compact device structure.
Solution Approach 2:
The patent employs a movable bending member that can dynamically reposition itself to process different groups of coil ends. The bending member moves in the circumferential direction to access different coil end groups sequentially. This dynamic positioning allows a single bending member to process all coil ends over time, achieving high productivity without requiring multiple large stationary molding jigs.
2Productivity
If multiple molding jigs are arranged in a circumferential shape to process all coil ends simultaneously, then all coil ends are molded at once, but the device complexity increases due to interference between adjacent molding jigs
Solution Approach 1:
The patent segments the coil ends into multiple groups that are processed in sequence. Instead of using multiple molding jigs arranged circumferentially to process all coil ends simultaneously, a single bending member processes one group at a time. This eliminates the complexity of coordinating multiple jigs and avoiding interference between them, while still achieving complete processing of all coil ends.
Solution Approach 2:
The single bending member is designed to be universal, capable of processing any group of coil ends by moving to the appropriate position. This multi-functional bending member replaces the need for multiple specialized molding jigs, simplifying the overall device structure while maintaining the ability to process all coil ends systematically.
3Productivity
If a large number of bending members are provided to process all coil ends, then all coil ends can be bent simultaneously, but the rigidity requirement for the device increases
Solution Approach 1:
The patent divides the coil ends into multiple groups and processes them sequentially with a single bending member. This segmentation means that at any given time, the bending member only needs to provide sufficient force for one group of coil ends rather than all coil ends simultaneously. This reduces the rigidity and strength requirements for the bending member and its supporting structure compared to a system that processes all coil ends at once.
Solution Approach 2:
The bending member is designed with dynamic positioning capability, allowing it to move to different locations around the stator core to process different groups of coil ends. This dynamic approach allows a single, less rigid bending member to perform the work that would otherwise require multiple highly rigid molding jigs, thereby reducing overall device rigidity requirements.
Data Source
AI summary
A method for manufacturing a stator includes an insertion step of inserting a plurality of segment coils into slots of a stator core, and a bending step of repeating, after the insertion step, a process in which a bending member that presses and bends a portion to be a coil end along the circumferential direction is relatively moved in a circumferential direction with respect to the stator core and relatively moved in an axial direction to bend the portion to be a coil end, and then bending is shifted to bending of the next portion to be a coil end adjacent to the bent portion to be a coil end by the bending member.