Bending-forming Jig for Stator Conductor Tips
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for forming stator coils face issues with bending U-shaped conductors, where increased bending leads to tip deformation and potential spattering during laser welding due to local heating, causing alignment and welding quality problems.
Innovation Solution
A bending-forming jig with an annular ring portion and claw portions that include abutting surfaces and a projecting portion to control the bending and positioning of U-shaped conductor tips, preventing deformation and ensuring proper alignment for stable welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the amount of bending of the protruding portions is increased to lower the coil end height, then the size of the motor is reduced, but the bending load may bend the tips of the protruding portions causing steps and spattering during laser welding
Solution Approach 1:
The patent introduces a bending-forming jig as an intermediary tool between the bending process and the tip portions of the protruding portions. The jig includes support portions that contact and support the tip portions during bending, preventing them from being bent or deformed. This mediator allows increased bending amount while maintaining tip portion levelness, thus reducing motor size without causing spattering during laser welding.
2Manufacturing precision
If the positions of the tip portions are aligned in the axial and circumferential directions using an alignment jig and fixed in the radial direction using a pressing jig, then welding alignment is achieved, but the device complexity increases
Solution Approach 1:
The patent merges the functions of multiple separate jigs (alignment jig and pressing jig) into a single integrated bending-forming jig. This unified jig performs both alignment and positioning functions simultaneously during the bending process, reducing the total number of jigs needed while maintaining precise welding alignment through the integrated support and positioning structures.
Data Source
AI summary
A bending-forming jig used in bending and forming a protruding portion of a leg portion of a U-shaped conductor toward a circumferential direction, the protruding portion protruding from an axial end surface of a stator core, the bending-forming jig including a ring portion and a claw portion, the claw portion including a first abutting surface that rises from an axial end surface of the ring portion with the surface directed in the circumferential direction and abuts against a tip portion of the protruding portion from the circumferential direction, and a projecting portion that projects, at a tip end of the claw portion, in the circumferential direction from the abutting surface and abuts against the tip portion of the protruding portion from the axial direction toward the axial end surface of the ring portion.