Stator Plug-In Coil End Detection Using 3D Laser Profiling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for detecting the position of plug-in coils in stators lack accuracy and reliability, particularly before and after welding, which can lead to suboptimal alignment and weld seam quality issues.
Innovation Solution
A method utilizing a profile sensor, such as a laser line sensor, to measure the 3-dimensional position of stator surfaces, identify measuring points associated with free ends, and determine directional indicators to accurately detect and align plug-in coils, ensuring correct positioning and weld seam quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional detection methods are used for plug-in coil positions, then the detection process is simple, but the measurement precision and reliability are insufficient
Solution Approach 1:
The patent replaces conventional mechanical or contact-based detection methods with optical measurement technology. A laser line sensor projects a laser line onto the stator surface and captures the reflected light pattern, converting physical coil position measurement into optical signal processing. This substitution achieves high measurement precision without mechanical contact, resolving the contradiction between accuracy and system complexity.
Solution Approach 2:
The patent introduces a laser line as an intermediary element between the measurement system and the plug-in coils. The laser line serves as a reference marker that interacts with the coil surfaces, enabling indirect measurement of coil positions through light reflection patterns. This intermediary approach allows precise detection while maintaining system simplicity through non-contact measurement.
2Reliability
If conventional detection methods are used, then the device complexity is low, but the reliability of detection before and after welding is insufficient
Solution Approach 1:
The patent replaces mechanical detection methods with optical measurement technology using a laser line sensor. This substitution provides reliable, non-contact measurement that can detect plug-in coil positions with high accuracy both before and after welding processes, eliminating the unreliability of conventional contact-based methods while maintaining reasonable system complexity through sophisticated optical sensing.
Solution Approach 2:
The patent implements a feedback mechanism where the laser line sensor continuously monitors plug-in coil positions and provides measurement data back to the control system. This feedback enables real-time verification of coil alignment and welding quality, significantly improving detection reliability by allowing corrective actions based on actual measured positions rather than relying on preset parameters.
3Manufacturing precision
If 3D measurements with directional indicators are implemented, then the manufacturing precision of stator assembly is improved, but the measurement and detection difficulty increases
Solution Approach 1:
The patent transitions from conventional 2D surface measurement to 3D spatial measurement by introducing the vertical dimension through laser triangulation. The laser line sensor captures not only horizontal position information but also vertical height data, creating comprehensive 3D point clouds that fully characterize plug-in coil positions and orientations. This dimensional expansion enables precise manufacturing control while the automated processing algorithms manage the complexity of 3D data analysis.
Solution Approach 2:
The patent replaces complex manual 3D measurement procedures with automated optical measurement technology. The laser line sensor system automatically captures 3D surface geometry and computes directional indicators through algorithmic processing, eliminating the need for manual coordinate measurement and complex mechanical measurement fixtures. This substitution reduces measurement difficulty while achieving high manufacturing precision through automated 3D data acquisition and analysis.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method provides a reliable and accurate detection of plug-in coil positions and shapes, enhancing the alignment process and weld seam quality by using 3D measurements and directional indicators, thereby improving the overall stator assembly precision.
Implementation Method 1
A laser line sensor can use triangulation to determine the distance of individual measuring points along a line to the sensor.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a method for detecting the position of free ends of plug-in coils in a stator.