Stator Coil Expansion Jig for Reliable Slot Insertion
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Solution Overview
Problem
Existing methods lack a specific device and method for easily and reliably inserting an annularly wound belt-shaped coil into slots from the inside of a stator core, as they do not provide a mechanism for expanding the coil diameter while inserting it.
Innovation Solution
A coil mounting device and method that utilize a coil winding jig with inter-comb-teeth grooves, a stator core fixing jig, and a coil expansion mechanism to expand the coil from inside to outside, allowing straight portions of the belt-shaped coil to be inserted into slots using the inter-comb-teeth grooves as a guide, with the expansion mechanism including a holder and a coil expander that increases the diameter of the coil end portions to facilitate insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the coil is wound around a cylindrical insertion jig and inserted inside the stator core, then the coil can be positioned inside the stator core, but the coil cannot be easily expanded in diameter to insert straight portions into slots
Solution Approach 1:
The coil winding jig is segmented into multiple comb teeth that can move relative to each other. The inter-comb-teeth grooves are formed between adjacent comb teeth, allowing the structure to be divided into expandable segments that can accommodate coil expansion while maintaining organizational structure
Solution Approach 2:
The coil winding jig is designed with movable comb teeth that can change the diameter of the jig dynamically. The comb teeth are configured to move apart radially, enabling the jig to expand from a compact insertion state to a larger diameter state that facilitates coil expansion and straight portion insertion into slots
2Reliability
If the coil is inserted inside the stator core without an expansion mechanism, then the device structure is simple, but the straight portions of the coil cannot be reliably inserted into the slots
Solution Approach 1:
The coil winding jig with inter-comb-teeth grooves serves as an intermediary device between the coil and the slots. The grooves guide and organize the straight portions of the coil, while the expandable structure of the jig mediates the transition from compact insertion to expanded positioning, ensuring reliable insertion into slots
Solution Approach 2:
The straight portions of the coil are preliminarily positioned in the inter-comb-teeth grooves before the expansion action. This preliminary arrangement ensures that when the jig expands, the straight portions are already organized and aligned for reliable insertion into the slots, improving insertion reliability
3Ease of manufacture
If the coil is expanded in diameter from inside toward outside, then the straight portions can be inserted into slots, but the coil structure becomes more complex during the process
Solution Approach 1:
The coil winding jig is designed to perform multiple functions automatically: it winds the coil, holds the straight portions in inter-comb-teeth grooves, and expands to facilitate insertion. The inter-comb-teeth structure self-organizes the coil portions during expansion, reducing the need for additional complex manipulation mechanisms
Data Source
AI summary
A coil mounting device includes a stator coil, a coil winding jig that has an outer diameter smaller than an inner diameter of the stator core and winds therearound a belt-shaped coil in an annular shape, a stator core fixing jig that fixes the stator core at a predetermined position and in a predetermined posture, and a coil expansion mechanism that expands the belt-shaped coil. The coil expansion mechanism includes a holder that holds the coil winding jig inside the stator core in a state where the inter-comb-teeth grooves are matched in phase with the slots, and a coil expander that expands the belt-shaped coil by pressing a portion nearer to a side end than the straight portions of the belt-shaped coil wound around the coil winding jig held by the holder so as to expand the portion, thereby inserting the straight portions into the slots.