Stator Coil Insertion Tool for 3D Coil Head Forming
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Solution Overview
Problem
The forming and assembly of three-dimensional coils into the stator of electric rotating machines require significant manufacturing effort and time, which is inefficient.
Innovation Solution
A tool with a cylindrical body and outer and inner tool grooves is used to form and insert coils into the stator, allowing simultaneous formation and insertion of coil heads by rotating the tool relative to the stator, reducing the complexity and time required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If formed coils are manually inserted into stator slots after three-dimensional forming, then coil assembly can be completed, but manufacturing effort and time are significantly increased
Solution Approach 1:
The patent combines the coil forming operation and coil insertion operation into a single integrated tool and process step. The tool simultaneously forms the three-dimensional coil shape and inserts it into the stator slot, eliminating the need for separate manual assembly operations that previously consumed significant time and effort.
Solution Approach 2:
The tool performs preliminary forming of the coil into its final three-dimensional shape with precise geometry before insertion into the stator slot. The coil is pre-formed with the exact spatial configuration needed, including proper positioning of coil sides and coil heads, so that no additional forming or adjustment is required during assembly.
2Manufacturing precision
If coils are formed into three-dimensional shape before insertion, then proper spatial arrangement is achieved, but manufacturing complexity increases
Solution Approach 1:
The tool employs segmented forming elements with discrete geometric features that correspond to specific portions of the coil structure. Each forming element is designed with specific shapes and dimensions that match the required coil geometry, allowing complex three-dimensional forming to be achieved through relatively simple, modular tool components rather than a monolithic complex device.
Solution Approach 2:
The patent introduces a forming tool as an intermediary device that temporarily holds and shapes the coil during the forming process. The tool provides the necessary geometric constraints and support structures to achieve precise three-dimensional coil formation, then releases the coil for insertion into the stator slot, avoiding the need for permanently complex tooling integrated into the assembly system.
3Manufacturing precision
If multiple forming steps are used to create three-dimensional coils, then coil shape accuracy is improved, but manufacturing effort and time increase
Solution Approach 1:
The patent merges multiple sequential forming operations into a single simultaneous forming action. The tool is designed with multiple forming surfaces and constraints that work together in one operation to create the complete three-dimensional coil shape, including coil sides, coil heads, and proper spatial positioning, eliminating the need for multiple separate forming steps.
Solution Approach 2:
The forming process maintains continuous contact and control over the coil throughout the entire forming operation. The tool applies continuous forming forces and maintains geometric constraints from the initial shaping through to the final configuration, ensuring high shape accuracy in a single uninterrupted action rather than through discrete steps with potential positioning errors between them.
Data Source
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AI summary
The invention relates to a method and a tool which allow coils to be shaped and introduced into a stator of an electric rotating machine. First and second coil sides of the coils are arranged in stator grooves, the tool is arranged in a cylindrical stator interior, and the second coil sides are introduced into outer tool grooves. Coil heads are then shaped by rotating the tool relative to the stator, and the second coil sides are introduced into the stator grooves by means of the tool.