Stator Conductor End Reshaping With Springback Compensation
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Solution Overview
Problem
Existing technologies face challenges in reshaping conductor pieces in a stator core prior to twisting, requiring a method that is both quick and precise.
Innovation Solution
An apparatus comprising a receptacle for the stator core, a bending unit with a positioning unit, a contact portion, and an actuator, which allows for precise reshaping of conductor pieces by moving the contact portion in a first and second bending direction to compensate for springback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional bending methods are used to reshape conductor pieces, then the reshaping process is simple, but springback causes imprecise positioning of the conductor piece ends
Solution Approach 1:
The bending apparatus pre-calculates and compensates for springback during the bending process by applying additional bending moment or adjusting bending parameters before the conductor piece is released. This preliminary action ensures that after springback occurs, the conductor piece achieves the desired final position and shape, eliminating the need for post-bending adjustments.
Solution Approach 2:
The system incorporates sensors to detect the actual position and shape of the conductor piece during and after bending. This feedback information is used to adjust bending parameters in real-time or for subsequent pieces, compensating for springback variations and ensuring consistent positioning precision across multiple conductor pieces.
2Productivity
If multiple conductor pieces are reshaped sequentially using traditional methods, then the process is simple to operate, but the productivity is low
Solution Approach 1:
The bending apparatus is divided into multiple independent bending units, each capable of reshaping one or more conductor pieces simultaneously. Each unit can operate independently or in coordination with others, allowing parallel processing of multiple conductor pieces without increasing the complexity of individual bending operations.
Solution Approach 2:
Multiple bending units are integrated into a single coordinated system that can process multiple conductor pieces in parallel. The system merges the functionality of multiple simple bending devices into one apparatus, achieving high productivity while maintaining operational simplicity through centralized control.
3Manufacturing precision
If the conductor pieces are bent to compensate for springback, then the positioning precision is improved, but the bending process time increases
Solution Approach 1:
Springback compensation parameters are pre-calculated and stored in the control system based on conductor piece material properties and geometry. During the bending process, these pre-determined compensation values are automatically applied, eliminating the need for time-consuming trial-and-error adjustments and reducing overall process time while maintaining high precision.
Solution Approach 2:
The system dynamically adjusts bending parameters such as bending speed, applied force, and holding time based on real-time feedback and pre-stored data. By optimizing these parameters, the system achieves the required positioning precision with minimal bending time, balancing quality and productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus enables rapid and precise reshaping of conductor pieces, effectively compensating for springback and ensuring the end portions align parallel to the longitudinal direction after bending.
Implementation Method 1
moving the contact portion in a first bending direction to bend the conductor piece around a first bending point and around a second bending point spaced apart from each other in the longitudinal direction of the conductor piece, wherein the end portion extending from the free end is held in its longitudinal orientation during the bending of the conductor piece
Implementation Method 2
pivoting the contact portion in a second bending direction counter to the first bending direction
Data Source
AI summary
The invention relates to an apparatus and a method for reshaping one or more conductor pieces arranged in a stator core, wherein a plurality of conductor pieces is arranged in the stator core, the conductor pieces being arranged on a plurality of circular paths running in a circumferential direction in rows which extend in a radial direction, and wherein the reshaping takes place in a free end of the conductor piece projecting out of the stator core.