Guide Jig for Stator Core Interphase Insulation Paper Insertion
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Solution Overview
Problem
Existing electric motor manufacturing methods face inefficiencies in inserting interphase insulation paper into stator cores due to time-consuming suction hold processes and potential position displacement, affecting productivity.
Innovation Solution
An electric motor manufacturing device featuring an insertion jig and guide jig system that uses vacuum pads to hold and deform the insulation paper, allowing precise insertion into stator core slots with reduced time and improved stability, eliminating the need for separate devices to push the paper further into slots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the holder suckingly holds the interphase insulator before insertion into the stator core, then the insulator can be positioned on the holder, but time is required for setting and position displacement may occur
Solution Approach 1:
The guide jig pre-forms the insulation paper into the target U-shape configuration before insertion, so that the paper is already in its final desired shape when inserted into the stator core. This eliminates the need for subsequent deformation steps and reduces assembly time while ensuring positional accuracy through the guiding structure.
Solution Approach 2:
The guide jig acts as an intermediary device between the insulation paper and the stator core. It receives the paper, deforms it into the correct shape, and guides it into the slots, thereby eliminating the need for separate deformation and insertion operations and reducing overall assembly time.
2Manufacturing precision
If the insulation paper is deformed before insertion into the stator core, then the paper can fit the slots, but the process requires additional time and steps
Solution Approach 1:
The guide jig combines multiple functions into a single device: it deforms the insulation paper into the U-shape, guides it into the correct orientation, and inserts it into the stator core slots all in one continuous operation. This merging of deformation and insertion processes eliminates separate steps and improves assembly speed while maintaining shape accuracy.
Solution Approach 2:
The guide jig performs the deformation action preliminarily during the insertion process itself, rather than as a separate pre-step. The paper is deformed into its final shape as it passes through the guide jig and is simultaneously inserted into the stator core, eliminating wasted time between deformation and insertion.
3Manufacturing precision
If a separate device is used to push the insulation paper into the slots, then the paper can be fully inserted, but the device complexity increases
Solution Approach 1:
The guide jig is designed as a multi-functional device that simultaneously performs deformation, guiding, and insertion functions. The guiding structure within the guide jig ensures proper insertion depth and orientation while the vacuum holder maintains paper position, eliminating the need for separate pushing devices and reducing overall system complexity.
Solution Approach 2:
The guide jig's guiding structure self-regulates the insertion process by physically guiding the deformed paper into the slots to the correct depth without requiring external forcing. The geometry of the guide jig itself provides the insertion force and depth control, eliminating the need for additional pushing mechanisms.
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 system enables accurate and efficient insertion of interphase insulation paper into stator cores, reducing assembly time and minimizing position displacement, thereby enhancing production efficiency and eliminating the need for additional devices to push the paper into slots.
Implementation Method 1
an interphase insulator insertion device structured to mount an interphase insulator to an inner periphery of a stator core, by using a holder structured to suckingly hold the interphase insulator
Data Source
AI summary
An inter-phase insulating paper is inserted, using a guide jig, into slots formed in the inner circumferential surface of a stator core. The guide jig is disposed at a predetermined position on one end surface side of the stator core. The inter-phase insulating paper is inserted into the guide jig along the stator core central axis line. The guide jig deforms the inter-phase insulating paper to a predetermined shape when the inter-phase insulating paper passes through the inside of the guide jig. The guide jig inserts both side portions of the inter-phase insulating paper simultaneously into different two slots of the stator core along the stator core central axis line.