Stator Hairpin Alignment Cover for Simultaneous Clamping and Masking
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Solution Overview
Problem
Existing methods for aligning and masking hairpins in stator production are complex, labor-intensive, prone to failure, and limited by cross-sectional geometry and the number of hairpin pairs that can be processed simultaneously, making them economically unsatisfactory.
Innovation Solution
A cover with recesses and aligning/tensioning means that allows for simultaneous alignment, masking, and connection of hairpin pairs, featuring a circular surface with concentric circular paths and radial webs, enabling easy positioning and clamping of hairpin ends without complex mechanisms, and can be produced using 3D printing for cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If individual stator segments are clamped and masked one after the other using clamping pins and flat masking plates, then the welding process can be performed, but the number of hairpin pairs that can be machined in one machine setting is limited and the method is not applicable for stators with multiple welding rings
Solution Approach 1:
The patent combines multiple clamping pins and masking plates into a single integrated cover component that performs both clamping and masking functions simultaneously. The cover includes multiple recesses that accommodate multiple hairpin pairs in one setting, eliminating the need for sequential processing of individual segments.
Solution Approach 2:
The cover is designed as a universal component that can accommodate stators with multiple welding rings and different numbers of hairpin pairs. The concentric circular paths and radial webs allow the same cover structure to process various configurations, making the device adaptable to different stator designs without requiring multiple specialized tools.
2Reliability
If full clamping and full masking are performed using cover plates with through holes or sheet metal strips, then all hairpin pairs can be secured, but the design becomes very complex especially regarding maintenance and repair
Solution Approach 1:
The cover is divided into functional sections with radial webs and annular webs that create distinct recesses for each hairpin pair. This segmentation allows individual recesses to be maintained or replaced without affecting the entire cover structure, simplifying repair operations while ensuring all hairpin pairs are securely clamped.
Solution Approach 2:
The cover design uses simple, easily manufacturable components that can be quickly replaced if worn or damaged. The straightforward geometry of recesses arranged on concentric circular paths with radial webs allows for cost-effective production and rapid replacement, reducing maintenance downtime and costs.
3Ease of manufacture
If openings are provided in the masking for hairpins with specific cross-sectional geometry, then welding can be performed, but metal particles generated during welding can block the twisting mechanism
Solution Approach 1:
The cover acts as an intermediary between the welding process and the hairpin pairs. The recesses provide precise accommodation for different cross-sectional geometries while the cover structure itself protects against metal particles blocking the mechanism. The tapered alignment means serve as intermediaries that guide hairpins into proper position without requiring complex twisting mechanisms.
4Manufacturing precision
If previously known alignment devices are used, then hairpin positioning can be achieved, but the process becomes complex and labor-intensive
Solution Approach 1:
The cover design enables self-alignment of hairpin pairs through the geometry of the recesses and tapered alignment means. The recesses are positioned and dimensioned to automatically guide hairpin ends into the correct relative positions during insertion, eliminating the need for complex external alignment devices or labor-intensive manual positioning procedures.
Data Source
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AI summary
The invention relates to a covering for simultaneously aligning and masking hairpins of a stator for preparing a welding operation, by means of which upper ends of the hairpins are connected. The covering comprises an in particular circular surface having an upper side and an underside, recesses, in which a respective arrangement comprising the upper sections of two hairpins arranged in pairs can be received, and means for aligning and clamping the upper sections of two hairpins arranged in pairs. The use of such a covering permits automatic centring and form-fitting clamping accuracy, the hairpin pairs being simultaneously masked. The invention further relates to a device comprising such a covering, to a method for connecting upper ends of hairpins of a stator by using such a covering, to a stator produced by this method, and to a system comprising a stator and a covering according to the invention.