Stator Conductor Insertion Device with Pre-Aligned Receptacle
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Solution Overview
Problem
Existing devices and methods for equipping stator cores with conductor pieces, such as hairpins, face challenges in achieving quick and precise insertion, often requiring manual alignment and deformation for welding, which can be time-consuming and prone to errors.
Innovation Solution
A device comprising a receptacle with play for loose conductor piece arrangement, a gripping device with alignment and counter-bearing mechanisms, and a twisting unit for deformation, allowing for automated and precise placement and alignment of hairpins within the stator core, enabling efficient and accurate insertion and deformation for welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conductor pieces are firmly fixed in the receptacle (form fit), then alignment precision is improved, but insertion difficulty increases and automation becomes complex
Solution Approach 1:
The conductor pieces are pre-aligned in the receptacle before the actual insertion process. The receptacle holds the conductor pieces in a predetermined configuration that matches their final position in the stator core, so that when the receptacle is inserted, the conductor pieces are already in the correct alignment without requiring complex alignment mechanisms during insertion
2Ease of operation
If conductor pieces are loosely arranged in the receptacle (with play), then insertion ease is improved, but alignment precision deteriorates
Solution Approach 1:
The conductor pieces are pre-positioned in the receptacle with play to allow easy insertion, but the receptacle itself is designed to provide the necessary alignment during the insertion process. The receptacle's geometry and the insertion mechanism work together to ensure that even loosely arranged conductor pieces achieve precise alignment automatically during insertion into the stator core
3Adaptability or versatility
If manual alignment and deformation is used, then flexibility is improved, but productivity decreases and errors increase
Solution Approach 1:
The device performs alignment and deformation operations automatically through self-contained mechanisms. The receptacle and insertion mechanism automatically align conductor pieces during insertion, and the twisting unit automatically deforms the connecting legs into the stator core without requiring manual intervention, thereby increasing productivity while maintaining process flexibility
Solution Approach 2:
Manual mechanical alignment and deformation operations are replaced by automated mechanical systems. The insertion device uses controlled mechanical forces to align and position conductor pieces, and the twisting unit uses automated mechanical rotation to deform the connecting legs, replacing manual operations with automated mechanisms that increase speed and reduce errors
Data Source
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AI summary
The invention relates to a device (10) for equipping a stator core (24) with conductor pieces (20) and to a method for equipping a stator core (24) with conductor pieces (20).