Stator Coil Shaping Apparatus Preventing Springback
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Solution Overview
Problem
In stator manufacturing, existing methods cause coil side parts to deform and expand, leading to coil end parts projecting axially, which results in an enlarged stator and potential popping out of side parts from slots due to springback after pushers are removed.
Innovation Solution
A stator manufacturing apparatus and method using an insertion tool with slit-like holding grooves, a pressing tool with plate-like pushers, and shaping tools to insert and shape coil side parts into slots, reducing coil end part heights and preventing side parts from popping out by pressing shaping tools against the coil end parts in an axial direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pushers are removed after inserting coil side parts into slots, then the insertion process is completed, but coil side parts pop out of slots due to springback
Solution Approach 1:
The patent applies preliminary action by performing shaping of the coil end parts immediately after inserting the coil side parts into the slots, while the coils are still under the influence of the pushers. This timing ensures that the coils are shaped before they can spring back, preventing the side parts from popping out of the slots. The shaping operation is conducted as a preliminary step to lock the coil configuration in place.
2Ease of manufacture
If coil side parts are inserted into slots by expanding spacing between them, then insertion is achieved, but coil end parts deform into chevron shape and project axially
Solution Approach 1:
The patent performs the shaping of coil end parts as a preliminary action immediately after insertion, while the pushers are still in place. This timing is critical because it shapes the coils before they spring back, preventing the formation of chevron shapes and axial projection. The preliminary shaping operation ensures that the coil end parts maintain their intended configuration.
Solution Approach 2:
The patent applies parameter changes by modifying the physical state of the coil end parts through shaping operations. By applying mechanical pressure during the shaping process, the coils undergo permanent deformation that reduces their height and eliminates the chevron shape. This changes the geometric parameters of the coil end parts from an expanded, deformed state to a compact, uniform state.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces coil end part heights and prevents side parts from popping out of slots, ensuring a compact and uniform stator assembly by shaping the coil end parts and maintaining their position within the slots.
Implementation Method 1
a part or all of the side parts inserted into the slots pop out toward a radially inner side from those slots due to so-called springback of the deformed coils to slightly return to an initial shape
Data Source
AI summary
A stator manufacturing apparatus includes an insertion tool that is insertable into a stator core and being configured to dispose a pair of side parts of a stator coil in two holding grooves. A pressing tool has plate-like pushers arranged to correspond to the positions of the holding grooves. The pressing tool pushes out the side parts of the stator coils and inserts the side parts into the corresponding slots. A pair of shaping tools face coil end parts of the stator coils. A plurality of slits through which the pushers are insertable are provided in a principal surface of each shaping tool. A shaping tool moving unit shapes the coil end parts by pressing the pair of shaping tools in an axial direction with the pushers inserted in each of the corresponding holding grooves.