Rotary Electric Machine Stator Assembly with Rotating Table
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Solution Overview
Problem
The existing methods for manufacturing rotary electric machines with annularly arranged divided core members require a wide space and result in damage to the coil leads and divided core members due to the radial extension of coil lead ends, necessitating skilled assembly and limited working space for the final core member placement.
Innovation Solution
A method involving winding coil strands on insulators surrounding divided iron cores, placing the core members on a rotating table, and inserting the coil ends into lead end holding grooves as each core member is positioned, allowing the ends to be pulled to terminal regions without radial extension, thereby reducing space requirements and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coil leads are wound on divided core members and arranged in annular pattern, then the stator structure is formed, but the coil lead ends extend radially outward requiring wide space
Solution Approach 1:
The coil lead ends are pulled into the lead end holding grooves at the time of inserting each divided core member, rather than waiting until all core members are assembled. This preliminary action prevents the radial extension problem before it occurs, eliminating the need for wide manufacturing space.
2Ease of operation
If coil lead ends are pulled after all divided core members are placed, then assembly is simplified, but the coil leads remain exposed and prone to damage
Solution Approach 1:
The coil lead ends are pulled into the protective grooves immediately when each divided core member is inserted, rather than delaying this action until all members are assembled. This ensures the coil leads are protected from damage throughout the entire assembly process while maintaining operational simplicity.
3Productivity
If the final divided core member is placed when two adjacent members are already installed, then the annular assembly is completed, but the working space is much smaller
Solution Approach 1:
By pulling the coil lead ends into the grooves at the time of inserting each divided core member including the final one, the operation becomes consistent and predictable. This eliminates the need for complex manual manipulation required in tight spaces, making the placement of the final core member as easy as the others.
4Reliability
If workers manually place divided core members avoiding contact with adjacent members, then damage is prevented, but high skill level is required
Solution Approach 1:
The coil lead ends are pulled into the grooves at the moment of inserting each divided core member, which naturally guides and positions the leads without requiring manual manipulation. This eliminates the need for workers to carefully avoid contact with adjacent members, reducing the skill requirement while maintaining protection against damage.
Data Source
AI summary
A coil strand is wound on an insulator to produce a divided core member, and then the divided core member is placed on a table. While the table rotates about its axis, ends of the coil strands are inserted into lead end holding grooves, which are defined in a surface of the insulator on an outer circumferential edge of a stator and which extend along a circumferential direction of the stator.