Stator Coil Alignment Member for Rotary Electric Machine Winding
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Solution Overview
Problem
Conventional methods for manufacturing stator coils in rotary electric machines result in misalignment and uneven intervals of straight portions, leading to reduced slot occupancy and power output due to offsetting and uneven superposition during the winding process.
Innovation Solution
A method involving the use of an alignment member with fitting grooves corresponding to the gap size between straight stack portions, allowing precise alignment and uniform spacing of straight portions during the winding process, along with the engagement of winding gears and conveyor gears to prevent positional offset, and the use of a separator/presser member to maintain stability during winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional winding methods are used without alignment members, then the winding process is simpler and faster, but misalignment and uneven intervals of straight portions occur, reducing slot occupancy and power output
Solution Approach 1:
An alignment member is introduced as an intermediary tool during the winding process. This alignment member includes fitting grooves that guide the straight portions of the integrated body, ensuring precise alignment and uniform intervals. The alignment member acts as a mediator between the integrated body and the core member, transferring the positioning function without requiring complex adjustment mechanisms.
Solution Approach 2:
The alignment member is prepared in advance with fitting grooves positioned at predetermined intervals corresponding to the desired spacing between straight stack portions. This preliminary preparation of the alignment member ensures that when the integrated body is wound, the straight portions are automatically positioned correctly without requiring real-time adjustment, thus improving alignment accuracy while maintaining process simplicity.
2Manufacturing precision
If alignment members with fitting grooves are used, then alignment accuracy and uniformity of straight stack portions are enhanced, but the device complexity and setup time increase
Solution Approach 1:
The alignment member is pre-configured with fitting grooves at precise intervals before the winding process begins. This preliminary setup ensures that when the integrated body is placed on the alignment member, the straight portions are automatically guided into correct positions, achieving uniform straight stack portions without requiring time-consuming adjustments during the winding process.
Solution Approach 2:
The fitting grooves in the alignment member and the straight portions of the integrated body are designed to fit together automatically through geometric constraints. This self-aligning mechanism eliminates the need for manual positioning or complex adjustment procedures, reducing setup time while maintaining high uniformity of straight stack portions.
3Manufacturing precision
If the integrated body is wound without alignment control, then the winding process is more flexible and adaptable, but offset in superposition occurs, reducing slot occupancy
Solution Approach 1:
The alignment member serves as a mediator that provides fixed reference positions through its fitting grooves. This intermediary structure guides the straight portions of the integrated body into precise alignment, ensuring accurate superposition without requiring complex active control systems. The alignment member maintains adaptability by allowing the integrated body to be placed on it and wound together as a unit.
Solution Approach 2:
The fitting grooves in the alignment member are pre-positioned at intervals that correspond to the desired spacing between straight stack portions. This preliminary positioning ensures that when the integrated body is wound, the straight portions automatically align with the correct positions, achieving accurate alignment while maintaining process flexibility through the simple placement-and-wind operation.
Data Source
AI summary
In manufacturing a stator coil for rotary electric machine having phase windings, plural conductive shaped wire members are integrated mutually to form an integrated body. Each shaped wire member has plural straight portions and plural turn portions alternately connecting adjacent straight portions at each of both ends of each straight portion. The body has plural straight superposed portions each formed by mutually superposing the plural straight portions. A wound-up body has plural straight stack portions The straight portions are fitted to respective fitting grooves of an alignment member, the fitting grooves being formed in the alignment member at intervals each corresponding to the size of a gap between adjacent straight stack portions. The integrated body is wound about a core member together with the alignment member, with the straight portions being fitted to the alignment member to form the wound-up body.