Stator Coil-End Holder Layout for Faster Conductor Joining
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Solution Overview
Problem
The existing manufacturing methods for stators are inefficient due to the time-consuming process of connecting multiple coil conductors, leading to increased man-hours and reduced productivity.
Innovation Solution
A holder system with rotatable positioning members is used to efficiently position and connect the ends of coil conductors, featuring an outer and inner annular member with holding portions and rod-shaped positioning members that rotate to align and secure the conductor ends, allowing for faster and more precise joining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple coil conductors are connected manually to form a stator coil, then the stator can be manufactured with proper assembly, but the manufacturing time increases and productivity decreases
Solution Approach 1:
The holder pre-positions all coil conductor ends in their correct spatial arrangement before the connection process begins. The positioning members hold each conductor end at predetermined locations, so that when connection proceeds, all components are already in optimal position, eliminating time-consuming alignment operations during assembly
Solution Approach 2:
The holder acts as an intermediary device between the coil conductors and the connection process. It provides a structured framework that facilitates efficient connection by maintaining proper spatial relationships among conductor ends throughout the manufacturing process, enabling faster and more reliable assembly
2Ease of manufacture
If coil conductor ends are positioned and connected using traditional methods, then connection can be achieved, but the process requires excessive time and manual operations
Solution Approach 1:
The holder is divided into multiple positioning members arranged circumferentially, each independently positioned to hold specific coil conductor ends. This segmentation allows parallel positioning of multiple conductors simultaneously, reducing the time required compared to sequential positioning methods
Solution Approach 2:
The positioning members extend in the radial direction, adding a radial dimension to the positioning system. This enables precise control of conductor end positions in three-dimensional space (axial, radial, and circumferential directions), facilitating faster and more accurate connection operations
Data Source
AI summary
A holder for positioning ends of coil conductors constituting a coil of a stator, wherein the ends of the coil conductors protrude in an axial direction and are arranged in the circumferential direction so as to form a row in the radial direction, comprises positioning members each configured to rotate about the radial direction as a rotation axis to bring a section of a positioning portion extending to the one side in contact with the ends forming the rows on one side in the circumferential direction, bring a section of the positioning portion extending to another side in contact with the ends forming the rows on another side, and thereby position the ends forming the rows together with the positioning portion of another adjacent positioning member.