Stator Coil Bending Jig for Precision Curvature Control
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Solution Overview
Problem
The existing manufacturing apparatuses for stators in rotating electric machines are unable to control the radii of curvature of coil protruding parts effectively, leading to increased axial dimensions and instability in joining the coil ends, resulting in variations in the radii of curvature and positional inaccuracies.
Innovation Solution
The proposed apparatus includes a supporting member and processing jigs with protruding parts that apply a load close to the stator core, allowing for controlled bending of coil protruding parts in the circumferential direction, reducing radii of curvature and improving positional accuracy by performing specific operations to align and bend the coil ends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing manufacturing apparatuses are used to bend coil protruding parts, then the bending operation can be performed, but the radii of curvature cannot be controlled effectively, leading to increased axial dimensions and positional inaccuracies
Solution Approach 1:
The processing jig is designed with a cylindrical part and multiple protruding parts that are positioned in advance to engage with the coil protruding parts before bending. The protruding parts apply a load close to the stator core, which preliminarily positions the bending point and controls the radius of curvature during the bending operation, thereby achieving precise control of the coil end positions while reducing the axial dimension.
2Reliability
If existing manufacturing apparatuses are used, then bending can be performed, but the joining of coil ends becomes unstable due to variations in radii of curvature
Solution Approach 1:
The processing jig is designed with multiple protruding parts that are arranged at predetermined intervals in the circumferential direction. These protruding parts apply distributed loads to the coil protruding parts during bending, providing feedback control on the bending process. This ensures that the radii of curvature are consistently controlled across all coil segments, thereby improving the reliability and stability of subsequent coil end joining operations.
3Manufacturing precision
If the axial dimension is reduced by controlling radii of curvature, then manufacturing precision is improved, but the device complexity increases due to the processing jig configuration
Solution Approach 1:
The processing jig is designed as a multi-functional device that combines several functions into a single apparatus. The cylindrical part provides radial positioning, while the multiple protruding parts simultaneously apply bending loads and control the radii of curvature. This universal design achieves precise control of coil protruding parts bending without requiring multiple separate devices, thereby limiting the increase in device complexity while maintaining high manufacturing precision.
Data Source
AI summary
An apparatus for manufacturing a stator includes a supporting member configured to support a stator core, at least one processing jig having a cylindrical part and a plurality of protruding parts, and an operating unit. The operating unit is configured to perform, in a state where each of coil protruding parts is inserted between one circumferentially-adjacent pair of the protruding parts of the processing jig and an axial end face of the stator core is located close to the protruding parts of the processing jig, a first operation and a second operation either simultaneously or alternately. The first operation is an operation of relatively rotating the stator core and the processing jig in a circumferential direction of the stator core. The second operation is an operation of relatively moving the stator core and the processing jig away from each other in an axial direction of the stator core.