Stator Core Stacking Using External Wedge Plates
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Solution Overview
Problem
Existing methods for stacking stator cores in electric machines are time-consuming and costly, requiring substantial precision and equipment installation within the stator core, which complicates maintenance and repair procedures.
Innovation Solution
A method involving pairs of plates with wedges inserted into slots of the stator core to facilitate precise alignment and secure stacking, utilizing a stacker with a crane arm and sliding devices for circular and plane motion to align and stack sheets horizontally, ensuring stability and efficient replacement of defective parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If devices with rails and dollies are installed inside the stator core to stack sheets, then stacking precision is improved, but device complexity and maintenance time increase
Solution Approach 1:
The patent removes the complex internal stacking devices (rails and dollies) from the stator core and replaces them with external positioning elements (plates with wedges) that are inserted into slots on the stator core periphery. This extraction eliminates the need for complex internal mechanisms while maintaining stacking precision through the wedge-locking system.
Solution Approach 2:
The patent introduces plates with wedges as intermediary elements that mediate between the stacking operation and the stator core. These plates are inserted into slots and use wedges to secure sheets in position, providing a simpler alternative to complex internal rails and dollies while achieving the same precision positioning function.
2Manufacturing precision
If devices are installed inside the stator core to stack sheets, then stacking precision is improved, but maintenance and repair procedures become more complex
Solution Approach 1:
By extracting the stacking devices from the internal stator core structure and replacing them with external plates and wedges inserted into peripheral slots, the patent makes maintenance and repair significantly easier. The external positioning elements can be accessed and replaced without disassembling complex internal mechanisms.
Solution Approach 2:
The patent segments the positioning function into separate, modular plates and wedges that can be independently inserted into slots. This segmentation allows individual components to be easily replaced or adjusted during maintenance, unlike integrated internal rail systems that would require complete disassembly.
3Device complexity
If traditional stacking methods are used, then equipment structure is simple, but stacking time and costs increase
Solution Approach 1:
The patent employs preliminary action by pre-positioning plates with wedges into slots before sheet stacking. This preparation enables rapid sheet insertion and securing without requiring complex internal mechanisms during the actual stacking operation, thus increasing productivity while keeping equipment relatively simple.
Solution Approach 2:
The wedge mechanism provides self-service by automatically securing sheets in position through friction and mechanical interlocking once inserted. This eliminates the need for complex active control systems or multiple adjustment mechanisms, maintaining simple equipment structure while achieving fast stacking through the self-securing nature of the wedges.
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
This method significantly reduces maintenance time by enabling fast and precise stacking of stator core sheets, maintaining core stability, and preventing misalignments, thus enhancing the efficiency of stator core repair and replacement processes.
Implementation Method 1
at least one wedge (25) is inserted between the two plates (23), wherein the wedge (25) secures the plates (23) in the slot (22) of the stator core (2)
Data Source
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AI summary
The present disclosure relates to a stacker and a method to assemble a stator core of an electric machine. Disclosed is a method for stacking a stator core of an electric machine, with the steps of providing a support adjacent to the stator frame to carry at least a sheet for the stator core, grabbing the at least a sheet with an arm arranged outside the stator core, the arm has a holding device for clamping the at least a sheet, guiding the at least a sheet inside the stator frame in a horizontal direction, and arranging the at least a sheet to compose the stator core.