Stator Coil Setting Apparatus with Rotating Retainer
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Solution Overview
Problem
Conventional methods for setting stator coils on a stator core using an inserter result in uneven coil arrangement, particularly where the first and last coils overlap, leading to reduced efficiency in rotating electrical machines.
Innovation Solution
A method and apparatus that utilize a retainer and rotating mechanism to maintain a phase difference between sections of stator coils, ensuring they are arranged at equal intervals in a radial pattern on the inserting blade before being mounted on the stator core, allowing for uniform spiral overlap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stator coils are manually formed and set on the inserter blade, then the manufacturing process is simple and flexible, but the arrangement of stator coils becomes uneven, particularly at the region where the first and last coils overlap
Solution Approach 1:
A coil setting device is introduced as an intermediary tool between manual coil formation and the inserter blade. This device includes a setting blade with multiple holding portions that temporarily hold stator coils in predetermined positions, ensuring uniform arrangement before transfer to the inserter blade. The setting blade acts as a mediator that standardizes the coil arrangement process while maintaining the simplicity of manual coil formation.
Solution Approach 2:
The stator coils are preliminarily arranged and held in uniform positions on the setting blade before being transferred to the inserter blade. The setting blade pre-establishes the correct spatial relationships and phase differences between coils, so that when coils are subsequently inserted into the stator core, they maintain uniform arrangement without requiring complex real-time adjustments during the insertion process.
2Productivity
If stator coils are set to overlap and form a spiral shape, then the coil structure is compact and efficient, but uneven arrangement reduces the efficiency of the rotating electrical machine
Solution Approach 1:
The setting blade serves as an intermediary device that ensures uniform arrangement of stator coils before they are inserted to form the spiral structure. By providing predetermined holding portions at specific intervals and positions, the setting blade guarantees that coils are evenly spaced and correctly phased, enabling the spiral arrangement to maintain both compactness and manufacturing precision.
Solution Approach 2:
The setting blade is divided into multiple holding portions, each responsible for holding a specific stator coil at a predetermined position. This segmentation allows each coil to be independently positioned and secured, ensuring uniform distribution around the circumferential direction. The holding portions are arranged to create the desired phase differences between adjacent coils, enabling precise control over the spiral formation.
3Manufacturing precision
If multiple stator coils are arranged at equal intervals in a radial pattern, then the phase difference between coil sections is controlled, but the device complexity increases with the need for rotating mechanisms
Solution Approach 1:
The setting blade is designed with asymmetric holding portions that are positioned at specific locations to create the required phase differences between adjacent coils. Rather than using symmetric, uniformly distributed holding portions, the blade incorporates asymmetric positioning that directly establishes the correct spatial relationships between coils. This asymmetric design simplifies the overall mechanism by embedding the phase difference control directly into the blade geometry rather than requiring additional adjustment mechanisms.
Data Source
AI summary
Stator coils are retained by an inserting blade and a setting blade. The setting blade is rotated in this state. Then, after rotation, the stator coils are set on the inserting blade. At this time, the stator coils are arranged in the inserting blade in a state where the stator coils overlap one another to form a spiral shape. Thus, the stator coils are arranged uniformly.