Stator Coil Insertion Guides to Prevent Insulator Twisting
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Solution Overview
Problem
Existing stator assembly methods risk catching and twisting insulating members when inserting a coil into a stator core, leading to potential damage and reduced assembly efficiency.
Innovation Solution
A stator assembly apparatus and method utilizing first and second guide members that support and sequentially retreat to maintain a stable slot width, preventing insulating member contact and twisting, with adjustable guide member thickness to accommodate coil tension and load changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two guide jigs are inserted into each slot to open insulating members before coil insertion, then the insulating members are prevented from being caught during initial insertion, but the coil still comes into contact with insulating members after guide jigs retreat, causing them to be twisted or buckled
Solution Approach 1:
The guide jig is divided into multiple segments: a first guide member that remains in the slot to maintain insulating member opening, and a second guide member that provides additional support. This segmentation allows different parts of the guide system to perform different functions at different stages of coil insertion, preventing both catching and buckling of insulating members.
Solution Approach 2:
The insulating members are opened and maintained in an opened state before coil insertion by the first guide member. This preliminary action ensures that when the coil is inserted, the insulating members are already in the correct configuration and remain stable throughout the insertion process, preventing subsequent twisting or buckling.
2Ease of manufacture
If guide jigs are used to insert coils from inside the stator core, then coil insertion is achieved, but the apparatus size increases due to the need for movable guide members and control mechanisms
Solution Approach 1:
The first guide member is extracted from the movable guide jig structure and fixed directly to the stator core. This extraction eliminates the need for complex movable mechanisms and control systems for the first guide member, significantly reducing apparatus size while maintaining the insulating member opening function. Only the second guide member remains movable, simplifying the overall system.
Solution Approach 2:
The first guide member serves multiple functions: it opens the insulating members, maintains them in an opened state during coil insertion, and provides a fixed reference structure. This multi-functionality reduces the need for additional separate components, thereby reducing apparatus complexity and size.
3Productivity
If the coil is pressed outward to move into insulating members, then coil insertion is achieved, but the insulating members may be caught between the coil and slot if not properly supported
Solution Approach 1:
The support function is segmented between the first guide member (fixed to stator core) and the second guide member (movable). The first guide member provides continuous support to maintain insulating member opening, while the second guide member provides additional support during the pressing operation. This segmentation ensures reliable insulating member stability throughout the high-speed insertion process.
Solution Approach 2:
The guide members act as intermediaries between the coil and the insulating members. They transmit and distribute the pressing force from the coil, preventing concentrated loads that could cause the insulating members to be caught or damaged. The intermediaries ensure smooth force transmission during high-speed insertion.
Data Source
AI summary
There are provided first guide members inserted into the insides of the insulating members in the slots, second guide members inserted into the insides of the insulating members and onto outer sides relative to the first guide members in a radial direction in the slots, and a controller controlling movement of each of the first guide members and the second guide members. After the first guide member moves outward in the radial direction in the slot until coming into contact with or close to a second guide member, the plurality of second guide members are caused to sequentially move to an outer side of the stator core in the central axis direction in order with the second guide member closest to the first guide members first and retreat from the slot as the coil is moved outward in the radial direction by the pressers.