Stator Fitting Tool Using Hydraulic Housing Expansion
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Solution Overview
Problem
The existing method of fitting a stator into a housing requires time-consuming heating and cooling processes, reducing the cycle rate and increasing production costs due to the need for extensive cooling storage space.
Innovation Solution
A tool and method utilizing a housing mounting, tool holder, and stator gripper with a pressure medium feed system to expand the housing wall elastically, allowing the stator to be inserted without heating, and then clamped in place as the pressure is released, eliminating the need for heating and cooling cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the housing is heated thermally to expand the housing wall for stator insertion, then the stator can be inserted through the housing opening, but the heating and cooling processes are time-consuming, reducing the cycle rate
Solution Approach 1:
The patent replaces the thermal heating system with a mechanical expansion system. A hollow expansion tool is inserted into the housing, and expansion elements (such as wedges or blades) are mechanically forced into the housing wall to expand it radially outward, creating sufficient opening for stator insertion without thermal processing.
Solution Approach 2:
The patent employs hydraulic or pneumatic pressure media to drive the expansion elements. A pressure medium (hydraulic fluid or compressed gas) is introduced into the expansion tool, generating the force needed to push the expansion elements into the housing wall and maintain expansion during stator insertion.
2Reliability
If the housing is heated and then cooled to fit the stator, then the stator is securely clamped by frictional engagement, but a large storage surface is required for cooling the housing
Solution Approach 1:
The patent extracts the cooling requirement entirely from the process. By using mechanical expansion instead of thermal heating, the housing never reaches elevated temperatures, so no cooling phase is needed and no cooling storage space is required. The expansion tool remains in place to maintain the expanded state during stator insertion and securing.
Solution Approach 2:
The expansion elements remain embedded in the housing wall, maintaining the expanded state passively through their mechanical presence. The housing itself serves to hold the expansion elements, which in turn maintain the expanded condition, eliminating the need for external cooling systems or storage space.
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 approach increases the cycle rate for fitting stators into housings and reduces production costs by eliminating the need for cooling processes and associated storage space.
Implementation Method 1
applying an internal pressure to the housing volume (38) and to the tool holder volume (26) by means of a pressure medium in such a way that a housing wall (42) surrounding the housing volume (38) is expanded elastically in the circumferential direction
Implementation Method 2
discharging the applied internal pressure, whereby the stator (12) is clamped to an inner lateral surface (46) of the housing wall (42) surrounding the housing volume (38)
Data Source
AI summary
Various embodiments include a tool for fitting a stator into a housing comprising: a housing mounting; a tool holder; and a stator gripper. The housing mounting includes a positioning device for holding the housing. The tool holder defines a tool holder volume and has a receiving opening. The stator gripper is arranged in the tool holder and moves between a first position and a second position. The stator gripper comprises a gripper head for holding the stator, in the first position, the gripper head is arranged in the tool holder volume and, in the second position, the gripper head is guided, at least in one section, through the receiving opening. The housing mounting and/or the tool holder move toward one another or away from one another. The housing mounting or the tool holder or the stator gripper includes a pressure medium feed opening.