Stator Coil Conductor Alignment via Rotational Inward Motion
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Solution Overview
Problem
Existing methods for aligning U-shaped electrical conductors in a stator coil fail to achieve high-density collection, leading to interference between adjacent conductor legs during alignment.
Innovation Solution
The method involves rotating U-shaped electrical conductors about a parallel shaft to reduce the diameter of the annular shape, allowing them to move towards the center, thereby avoiding interference between adjacent conductors and enabling efficient alignment without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If electrical conductors are arranged in an annular shape and moved towards the center to achieve high-density collection, then the density of conductor collection is improved, but adjacent conductor legs interfere with each other during alignment
Solution Approach 1:
The patent introduces a rotational dimension to the alignment process. Instead of simply moving conductors linearly towards the center, each conductor is rotated about a shaft parallel to the central axis while moving radially inward. This dimensional change allows conductors to spiral into their final positions, reducing interference between adjacent legs during the alignment process.
Solution Approach 2:
The alignment process employs dynamic movement where conductors are continuously rotated and translated simultaneously. The gripping devices rotate the conductors about parallel shafts while moving them towards the center, creating a dynamic alignment process that prevents static interference between adjacent conductor legs.
2Device complexity
If conventional alignment methods using housing grooves or holes are used, then alignment structure is simple, but high-density collection of conductors cannot be achieved
Solution Approach 1:
The patent changes the alignment approach from static positioning in housing grooves or holes to dynamic rotational movement. By altering the movement parameters (adding rotation about parallel shafts while moving radially inward), the system achieves higher conductor density without significantly increasing structural complexity.
Solution Approach 2:
The gripping devices serve multiple functions: they grip the conductors, rotate them about parallel shafts, and move them radially towards the center. This multi-functionality allows the alignment structure to achieve high-density collection without requiring separate complex mechanisms for each function.
Data Source
AI summary
Provided are an alignment method and an alignment device by which, immediately before aligning, the leg parts of adjacent conductors do not interfere with each other. The alignment method, in which by providing a plurality of coil elements (40) in an annular shape and moving the plurality of coil elements (40) in a direction in which the diameter of the annular shape is reduced, the plurality of coil elements (40) are aligned in a state where turn sections (42) provided at substantially apex portions are alternately overlapped, wherein the plurality of coil elements (40) are aligned by moving each of the plurality of coil elements (40) toward an annularly shaped center, and while doing so, rotating the plurality of coil elements about a rotation axis (231e) that is parallel to the central axis (C1) of the annular shape.