Automated Bending Fixture for Stator Conductor Ends
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Solution Overview
Problem
The existing methods for manufacturing motor stators using flat or square wire windings are labor-intensive and not suitable for mass production due to the need for manual bending and interconnection of hairpin-shaped conductors, which is slow and inefficient.
Innovation Solution
A method and apparatus for simultaneously bending the ends of stator conductors to specific angles using a bending fixture with concentric ring-like members and pneumatic actuators, allowing for automated interconnection and phase separation, enabling efficient and precise bending of conductors across multiple slots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual bending and interconnection of hairpin-shaped conductors is used, then manufacturing precision can be achieved, but productivity is low and labor intensity is high
Solution Approach 1:
The patent replaces manual mechanical bending operations with an automated bending machine that uses a bending fixture and actuating mechanism. The machine automatically positions and bends conductor ends to predetermined angles, eliminating hand bending while maintaining precision through mechanical guidance and controlled actuation.
Solution Approach 2:
The bending fixture is designed to automatically position multiple conductor ends simultaneously and bend them to the correct angles without requiring operator intervention for each conductor. The apparatus performs the bending operation autonomously once positioned, allowing rapid processing of multiple conductors in sequence or parallel.
2Ease of operation
If hand bending of conductors is performed one at a time, then ease of operation is maintained, but loss of time is significant
Solution Approach 1:
The bending fixture is designed to hold and bend multiple conductor ends simultaneously or in rapid succession. The apparatus combines multiple bending operations into a single setup, allowing all conductor ends for a given phase or group to be bent in one continuous operation rather than individually.
Solution Approach 2:
The fixture is pre-configured with positioning elements and bending surfaces that automatically guide conductors to the correct positions and angles. The apparatus performs preliminary positioning and alignment before bending, so that when actuation occurs, all conductors are ready for immediate bending without requiring manual adjustment during the operation.
3Productivity
If automated bending apparatus is introduced, then productivity increases, but device complexity increases
Solution Approach 1:
The bending apparatus is divided into distinct functional modules: a fixture for holding conductors, positioning elements for alignment, an actuating mechanism for bending, and a control system. Each module performs a specific function and can be independently adjusted or replaced, making the complex system manageable and adaptable to different production requirements.
Data Source
AI summary
Methods and apparatus for twisting rectangular rotor and stator conductor ends whereby most if not all conductor ends are bent at once, radially adjacent ends being bent in opposite directions. A lost motion member may be used to bend selected conductors through lesser angles for such purposes as phase interconnection and power leads. The rectangular conductors are retained against twisting so that flat conductors will bend about an axis perpendicular to the larger dimension of the conductor cross section. Various features of the methods and apparatus are disclosed.