Stator Assembly Using Guide Jig to Prevent Insulation Deformation
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Solution Overview
Problem
In existing stator assembly methods, the insulating member is often deformed during the insertion of a slot-housed portion into a stator core slot, leading to inadequate insulation between the slot-housed portion and the slot, as the insulating member is compressed and can become slackened, causing mechanical interference and reduced insulation effectiveness.
Innovation Solution
A stator assembly method and apparatus that uses a first guide jig to open a portion of the insulation radially, allowing the slot-housed portion to be inserted into the slot while maintaining the insulation's shape, preventing deformation by using an urging force to keep the guide jig and slot-housed portion in contact, thus ensuring reliable insulation between the coil and the stator core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the slot-housed portion is moved while being pressed from the radially inner side toward the radially outer side, then the slot-housed portion can be inserted into the slot, but the slot-housed portion may spring back to the radially inner side causing the insulating member to deform
Solution Approach 1:
A guide jig is introduced as an intermediary tool between the pressing mechanism and the slot-housed portion. The guide jig includes a guiding surface that guides the slot-housed portion during insertion, preventing springback and insulating member deformation while enabling efficient pressing operation
Solution Approach 2:
The guide jig is positioned in advance within the insulating member before the slot-housed portion is inserted. The guiding surface is pre-configured to provide the necessary guidance path, preventing deformation before it can occur during the insertion process
2Productivity
If the insulating member is compressed during insertion, then the slot-housed portion can be inserted into the slot, but the insulating member becomes slackened and deformed reducing insulation effectiveness
Solution Approach 1:
The guide jig acts as a mediator that distributes the pressing force through its guiding surface, preventing concentrated compression of the insulating member. This maintains the insulating member's shape and insulation effectiveness while enabling insertion
Solution Approach 2:
The guide jig changes the pressure distribution parameters by providing a distributed contact surface through its guiding surface, transforming the concentrated pressing force into a distributed force that prevents insulating member deformation
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 securely inserts the slot-housed portion into the stator core slot without deforming the insulation, maintaining effective insulation and preventing mechanical interference, thereby ensuring reliable electrical insulation and reducing the risk of electrical failures.
Implementation Method 1
opening a portion of the insulation on the one side in the radial direction by inserting a first guide jig into the insulation
Implementation Method 2
inserting the slot-housed portion includes inserting the slot-housed portion into the slot via the opening by moving the coil and the first guide jig together toward the other side in the radial direction with respect to the stator core against an urging force
Data Source
AI summary
A stator assembly method of assembling a stator that includes a stator core that includes a slot that has an opening that opens on one side in a radial direction, a coil that includes a slot-housed portion housed in the slot, and insulation disposed between the slot and the slot-housed portion, the method including disposing the insulation in the slot; opening a portion of the insulation on the one side in the radial direction by inserting a first guide jig into the insulation, which is disposed in the slot, along a center axis direction of the stator core, after disposing the insulation; and inserting the slot-housed portion into the slot via the opening by moving the coil and the first guide jig together toward the other side in the radial direction with respect to the stator core, after opening the portion of the insulation.