Stator Coil Insertion Layout to Prevent Springback Gaps
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Solution Overview
Problem
The issue of coil end portions returning inward due to springback after insertion into stator core slots, leading to poor workability in coil insertion processes, is addressed.
Innovation Solution
A coil insertion device and method utilizing a coil presser to expand coil end portions outward and a restrictor to prevent inward movement, ensuring the coil end portions are sandwiched between the presser and restrictor, thereby offsetting springback and eliminating gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If coil end portions are pressed outward to expand diameter for slot insertion, then coil insertion is achieved, but coil end portions return inward due to springback after pressure release
Solution Approach 1:
The restrictor is positioned to preemptively counteract the springback force before the coil can return inward. By establishing a physical barrier at the slot opening, the system prevents the harmful inward movement before it occurs, maintaining the expanded diameter state achieved during insertion.
Solution Approach 2:
The coil presser expands the coil diameter and inserts it into the slots before the restrictor engages. This preliminary expansion action prepares the coil for insertion, and the restrictor then maintains this expanded state by preventing springback, ensuring proper positioning without requiring repeated pressing operations.
2Stability of the object's composition
If coil end portions are repeatedly pressed to prevent springback, then coil position stability is improved, but workability deteriorates
Solution Approach 1:
The restrictor provides a single preliminary anti-action by blocking the inward springback movement. This one-time preventive measure eliminates the need for repeated pressing operations, significantly improving workability while maintaining coil position stability throughout the process.
3Ease of manufacture
If coil end portions expand in diameter during insertion, then slot insertion is facilitated, but gaps appear between coils after springback
Solution Approach 1:
The restrictor prevents inward springback that would create gaps between coils. By maintaining the expanded diameter state, the restrictor ensures that coils remain properly spaced and aligned in the slots, eliminating the manufacturing precision issues that would otherwise result from springback.
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
Prevents coil return due to springback, improves workability, and ensures even coil layout on the stator core end face, while also securing space for rotor insertion.
Implementation Method 1
presses coil end portions outward from inside to expand the coil end portions in diameter
Implementation Method 2
restrictor that is arranged outside the coil assembly, restricts outward movement of the coil end portions expanded in diameter by the coil presser, and sandwiches the coil end portions of the coil assembly inserted in the slots with the coil presser
Data Source
AI summary
A coil insertion device includes coil diameter expanders, the coil diameter expanders being configured to insert a coil assembly in a wound state into slots of a stator core by expanding the coil assembly in diameter from inside of the stator core, each of the coil diameter expanders includes: a coil presser that is arranged inside the coil assembly and presses coil end portions of the coil assembly outward from inside to expand the coil end portions in diameter; and a restrictor that is arranged outside the coil assembly, restricts outward movement of the coil end portions expanded in diameter by the coil presser, and sandwiches the coil end portions of the coil assembly inserted in the slots with the coil presser.