Slot Liner Flaring Tool for Stator Assembly
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Solution Overview
Problem
Die cut magnet wire tips are often sharp with burrs, leading to risks of cutting or ejecting slot liners during assembly, and process variations cause inconsistent retention in slot liners, affecting the assembly process of electro-dynamic machines.
Innovation Solution
A slot flaring apparatus with a base and flaring tool, featuring a plurality of flaring teeth that can be controllably pressed against a stator to form a consistent crown end in slot liners, reducing the risk of damage and improving retention, and optionally includes a heating element to conductively shape the liners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If die cut magnet wire tips are used, then wire insertion is enabled, but sharp tips with burrs cause cutting or ejection of slot liners
Solution Approach 1:
The slot liner is pre-flared at its crown end before wire insertion to create a rounded, enlarged opening. This preliminary shaping action prepares the slot liner to accommodate sharp wire tips without damage, preventing the harmful effects of cutting or ejection during the subsequent wire insertion operation.
2Ease of manufacture
If standard slot liners are used, then assembly is simplified, but process variation creates inconsistent retention for each individual slot liner
Solution Approach 1:
The slot liner's crown end geometry is modified through flaring to create a standardized enlarged opening with specific dimensional parameters. This parameter change in the slot liner structure compensates for material variations and ensures consistent retention characteristics across all slot liners, improving reliability while maintaining assembly simplicity.
3Adaptability or versatility
If slot liner retention varies, then individual liner performance differs, but assembly consistency and quality control deteriorate
Solution Approach 1:
A preliminary flaring operation is performed on the crown end of each slot liner to create a standardized enlarged opening. This pre-treatment ensures that all slot liners have consistent geometric parameters at their openings, which improves assembly consistency and quality control while allowing individual liners to maintain their inherent performance characteristics.
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
The solution provides a fast and consistent method to form slot liners, preventing push-out and damage during assembly, enhancing ease of assembly and reducing wire insertion risks, while accommodating various liner types and assembly methods.
Implementation Method 1
The slot flaring apparatus may further yet include a heating element on the flaring tool and is configured to conductively heat the plurality of flaring teeth
Data Source
AI summary
A slot flaring apparatus is presented herein. The slot flaring apparatus includes a base and flaring tool. The base is configured to receive and secure a stator that has a plurality of core slots. The flaring tool is configured to be controllably pressed against the stator and has a plurality of flaring teeth. Moreover, each tooth of the plurality of flaring teeth is configured to insert into and form a respective slot liner which has been inserted into the corresponding core slot.