Stator Busbar Fixture Alignment for Pre-Set Stack Height
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Solution Overview
Problem
Ensuring proper alignment and stack height of a busbar relative to a stator core during assembly of electric machines is challenging, as adjusting these parameters after insertion into a housing is difficult and often results in improper interfaces and fits.
Innovation Solution
A fixture system comprising a first and second fixture portion with alignment features that securely hold the stator core and busbar, allowing for precise alignment and establishment of a selected stack height, ensuring correct orientation and positioning before mounting into a housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the busbar is welded to the stator core before mounting in the housing, then the electrical connection is established, but the alignment between the busbar and stator core becomes difficult to adjust
Solution Approach 1:
The fixture establishes the alignment between the busbar and stator core before the welding operation. The alignment features pre-position the busbar relative to the stator core windings, ensuring proper alignment is achieved prior to permanent attachment, thus resolving the contradiction between establishing reliable electrical connection and maintaining alignment adjustability
2Strength
If the stator is inserted into the housing after assembly, then the housing protection is provided, but the stack height adjustment becomes difficult
Solution Approach 1:
The fixture establishes the selected stack height of the stator core before the stator is inserted into the housing. The fixture portions support the stator core at a predetermined height, ensuring the correct stack height is achieved prior to housing insertion, thus resolving the contradiction between providing housing protection and maintaining stack height adjustability
3Device complexity
If manual alignment methods are used, then the equipment complexity is reduced, but the alignment precision deteriorates
Solution Approach 1:
The fixture acts as an intermediary device between the busbar and stator core during assembly. The alignment features on the fixture provide precise geometric references that guide the relative positioning, achieving high alignment precision without requiring complex alignment equipment or procedures
Data Source
AI summary
A fixture for holding a stator including a stator core having a plurality of stator windings during assembly. The fixture includes a first fixture portion including a base defining a first stator receiving portion that is receptive of a first end of the stator, a second fixture portion including second stator receiving portion that is receptive of a second end of the stator, and at least one alignment feature provided on one of the first fixture portion and the second fixture portion. The at least one alignment feature is configurated to establish a selected alignment between a terminal end of each of the plurality of stator windings and busbar.