Stator Core Skew Correction Device and Method

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Solution Overview

Problem

Stator cores in rotary electric machines experience lamination shift or skew due to the insertion of electrical conductors into slots and twisting and bending of their leading ends, which is difficult to correct without special processing.

Innovation Solution

A skew correction device that includes a support member, a first pressurizing mechanism to press the support member radially inward, and a rotation mechanism to correct the skew by rotating the support member, with optional positioning and measuring components to accurately assess and address the skew.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If electrical conductors are inserted into slots and leading ends are twisted and bent in the circumferential direction, then the stator core can be assembled with coil elements, but lamination shift (skew) occurs in the circumferential direction

Engineering Contradiction:

Improveease of assemblyVSAvoidlamination alignment

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The support member is positioned in advance to hold the protrusions before the skew correction process begins. The support member is preliminarily inserted into the stator core to establish a reference position, and then the stator core is rotated relative to the support member to correct the skew. This preliminary positioning enables the subsequent correction action to be effective.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The stator core's own protrusions are utilized as the correction targets. The protrusions that naturally form on the stator core during assembly are used as reference points for the skew correction process. The support member engages with these existing protrusions to enable correction without requiring additional external fixtures or complex setup procedures.

Inventive Principle:

Principle #25Self-service

2Strength

If fastening members are inserted and jammed in fastening holes of projecting parts, then the stator core can be held together, but positional shift of layered thin sheets can occur

Engineering Contradiction:

Improvestructural integrityVSAvoidlamination alignment

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The support member acts as an intermediary reference object during the skew correction process. It provides a stable external reference that the stator core can be aligned against, mediating between the stator core's protrusions and the correction rotation mechanism. This intermediary enables precise alignment without requiring the fastening members themselves to serve as alignment references.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If skew correction is performed by rotating the support member with pressurizing mechanism, then lamination shift can be corrected, but device complexity increases

Engineering Contradiction:

Improvelamination alignmentVSAvoidcorrection mechanism

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The support member serves multiple functions: it provides a reference position for alignment, engages with the protrusions for correction, and acts as a mechanical interface for the rotation mechanism. The pressurizing mechanism not only applies force but also maintains contact between the support member and protrusions during rotation. This multi-functionality reduces the need for separate components for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention replaces complex measurement and adjustment systems with a purely mechanical rotation mechanism. Instead of using sensors, motors, and control systems to detect and correct skew, the patent uses a mechanical pressurizing and rotation system that directly physically corrects the alignment through controlled rotation relative to the support member.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 device effectively corrects skew in the circumferential direction of stator cores without requiring special processing on the stator core, allowing for precise measurement and confirmation of skew correction.

Implementation Method 1

a first pressurizing mechanism (72) that presses the support member (71) towards an inner side in a radial direction of the stator core

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

a rotation mechanism (73) that corrects the lamination shift in the circumferential direction by causing the support member (71) to rotate in a direction in which the lamination shift in the circumferential direction is corrected with the radial direction as an axis of rotation

Methodology Applied

Scientific EffectMechanical Rotation: Mechanical Force

Data Source

PatentUS9960661B2Skew correction device for stator core and skew correction method

Publication Date: 2018.05.01 HONDA MOTOR CO LTD

AI summary

A skew correction device is provided that can easily correct the skew in the circumferential direction of the stator core arising due to insertion of electrical conductors into each slot and twisting and bending of the leading ends thereof in the circumferential direction. A skew correction device (10) for stator cores (2), includes: a support member (71) capable of supporting from outwards a protrusion (5) formed by the plurality of projecting parts (21) aligning; a first pressurizing mechanism (72) for pressing the support member (71) towards an inner side in a radial direction; and a rotation mechanism (73) for correcting skew in the circumferential direction, by causing the support member (71) to rotate in a direction in which the skew in the circumferential direction is corrected by way of a rotating shaft (731), in a state supporting the protrusion (5) from outwards by pressing the support member (71).