Stator Coil Expander for Uniform Slot Insertion
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Solution Overview
Problem
Conventional methods for inserting an annularly wound coil into stator core slots require multiple rotations and result in unstable diameter expansion, leading to increased man-hours and potential coil instability due to partial circumference pressing.
Innovation Solution
A coil insertion device with annularly arranged piece members that can move from a reduced diameter position inside the coil to an expanded position, allowing the coil to be inserted efficiently and stably into the slots by expanding over the entire periphery, maintaining a continuous outer surface without gaps between adjacent pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single roller is used to press the coil from inside, then the device structure is simple, but the coil insertion efficiency is low and requires multiple rotations
Solution Approach 1:
The coil pressing mechanism is segmented into multiple piece members (first, second, third, and fourth piece members) arranged circumferentially around the coil. Each piece member independently presses a different section of the coil, enabling simultaneous multi-point pressing that eliminates the need for multiple rotations and significantly improves insertion efficiency.
2Reliability
If the roller presses only part of the coil circumference, then the device structure is simple, but the coil diameter stability deteriorates
Solution Approach 1:
The pressing mechanism is divided into multiple piece members positioned at different circumferential locations. This segmentation allows each piece member to press a specific section of the coil, ensuring uniform diameter expansion and stable coil formation throughout the entire circumference, thereby improving reliability.
Solution Approach 2:
Multiple piece members are combined to work simultaneously on different sections of the coil. By merging their pressing actions, the system achieves uniform coil expansion and stable diameter control that a single roller cannot provide, while maintaining structural efficiency.
3Productivity
If multiple rotations are performed to insert the entire coil, then complete insertion is achieved, but the required time increases
Solution Approach 1:
The coil insertion operation is segmented into simultaneous multi-point pressing actions by multiple piece members. This allows the entire coil circumference to be pressed and inserted in a single operation, eliminating the need for multiple rotations and significantly reducing insertion time.
Solution Approach 2:
The piece members are pre-positioned around the coil at appropriate circumferential locations before the insertion operation begins. This preliminary arrangement enables immediate multi-point pressing upon activation, allowing complete coil insertion in a single action without requiring sequential rotations.
4Reliability
If the coil is expanded non-uniformly, then the insertion process is simpler, but the coil posture stability deteriorates
Solution Approach 1:
The expansion mechanism is segmented into multiple piece members distributed circumferentially, each responsible for pressing a specific coil section. This segmentation ensures that expansion forces are applied uniformly across the entire coil circumference, maintaining coil posture stability and preventing deformation.
Solution Approach 2:
The piece members are positioned at asymmetric intervals around the coil, with different angular spacings between adjacent members. This asymmetric arrangement allows the mechanism to accommodate varying coil geometries while still achieving uniform expansion, as each piece member independently adjusts to its local coil section.
Data Source
AI summary
Provided is a coil insertion device for inserting a wound coil into slots formed in a stator core and opening to a through-hole of the stator core, by placing the coil in the through-hole, and by expanding the coil to move the coil from inside toward outside with respect to the stator core. The coil insertion device includes a coil expander having a plurality of piece members arranged in an annular shape. The plurality of piece members are movable between a first position where the plurality of piece members are reduced in diameter so as to be insertable inside the wound coil, and a second position where the plurality of piece members are expanded in diameter from the first position to press the wound coil from inside toward outside, thereby inserting the wound coil into the slots at once.