Stator Coil Assembly Using Flat Plate Guide Jigs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stator assembly methods and apparatuses deform coil end portions, leading to increased insertion load and potential flaws during the assembly of coils into annular stator cores, resulting in shape degradation and equipment size increases.
Innovation Solution
A stator assembly method and apparatus that utilize guide jigs to form guide surfaces parallel to the stator core teeth, allowing coils to be inserted with reduced deformation, thereby minimizing the insertion load and preventing shape flaws by guiding slot housed portions into slots while maintaining the coils' original shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coils are assembled to a jig in a generally circular column shape with holding grooves, then the coils can be mounted to the stator core, but the coil end portions are deformed and work-hardened, increasing insertion load
Solution Approach 1:
The invention divides the coil assembly process into two distinct stages: first assembling coils to a flat plate-shaped jig to form a coil assembly, then transferring the entire assembly to the stator core. This segmentation prevents deformation during the critical insertion phase while maintaining manufacturing ease.
Solution Approach 2:
The flat plate-shaped jig serves as an intermediary tool that holds coils in their natural, undeformed state during assembly. The jig's flat plate structure with recesses provides support without imposing the deformations that would occur with a circular column-shaped jig, thereby reducing insertion load.
2Ease of manufacture
If coils are deformed to fit the jig, then the coils can be assembled to the stator core, but the shape accuracy of the coils degrades
Solution Approach 1:
The invention separates the coil assembly formation from the stator core mounting process. Coils are assembled to a flat plate-shaped jig that preserves their original shape, then the entire assembly is transferred to the stator core. This segmentation maintains shape accuracy while enabling assembly.
Solution Approach 2:
The flat plate-shaped jig acts as an intermediary that supports coils without deforming them. The recesses in the jig accommodate the coil end portions in their natural configuration, preventing work-hardening and shape degradation that would occur with conventional circular jigs.
3Strength
If the interval of holding grooves is smaller at positions closer to the center of the jig, then the coils can be held securely, but the coil end portions undergo significant deformation
Solution Approach 1:
The invention applies local quality by providing recesses only at specific locations on the flat plate-shaped jig where coil end portions need support. The recesses are positioned to accommodate the linear oblique portions of the coil end portions without forcing deformation, while the rest of the jig maintains a simple flat plate structure.
Solution Approach 2:
Instead of making the jig conform to the coils (which would require complex circular geometry with varying groove intervals), the invention inverts the approach: the flat plate-shaped jig maintains a simple, uniform structure, and the coils are positioned to fit the recesses. This eliminates the need for variable groove intervals and prevents deformation.
Data Source
AI summary
A stator assembly method in which coils that have slot housed portions and coil ends formed from a conductive wire are mounted to an annular stator core that has a plurality of teeth that extend from a back yoke toward an inner side in a radial direction and slots formed between two of the teeth.