3D Vision Feedback Control for Stator Hairpin Forming
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Solution Overview
Problem
Conventional methods for producing conductor elements or hairpins for inductive windings of stators rely heavily on human operators for quality checks, leading to subjective decisions, long reaction times, and instability due to external interference and working conditions, resulting in significant rework and waste.
Innovation Solution
A system and method utilizing a 3D vision device and monitoring device to generate 3D reconstructions of conductor elements, assess characteristic measures, and automatically correct forming machine parameters to maintain quality within predefined tolerance windows, independent of human operator variability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If human operators perform periodic quality checks using magnification devices, then quality assessment is possible, but reaction time is long and decisions are subjective
Solution Approach 1:
The patent replaces the mechanical visual inspection system used by human operators with an automated optical measurement system. The forming machine includes integrated sensors and measurement devices that automatically measure conductor element dimensions during production, eliminating the need for manual magnification-based inspection and enabling real-time objective quality assessment.
Solution Approach 2:
The patent implements a feedback control system where measurement data from the automated inspection system is immediately fed back to the control unit. The control unit compares measured dimensions against tolerance specifications and automatically adjusts forming parameters or alerts operators, creating a closed-loop system that reduces reaction time and eliminates subjective decision-making.
2Adaptability or versatility
If forming operations are performed manually with periodic checks, then flexibility is maintained, but process stability deteriorates due to external interference
Solution Approach 1:
The patent employs continuous feedback control where measurement data from each produced conductor element is immediately used to adjust forming parameters. This closed-loop control compensates for external disturbances such as material hardness variations and temperature changes, maintaining process stability while allowing adaptive response to actual conditions.
Solution Approach 2:
The forming machine performs self-correction through automated measurement and control systems. The machine automatically detects deviations in conductor element dimensions and adjusts its own operating parameters without human intervention, enabling the system to self-correct for external interference and maintain stable production quality.
3Device complexity
If conventional forming machines are used without integrated monitoring, then device complexity is low, but manufacturing precision deteriorates due to drift outside tolerance window
Solution Approach 1:
The patent merges the forming operations and quality measurement functions into a single integrated system. The forming machine includes built-in sensors, measurement devices, and control units that work together during the forming process, eliminating the need for separate post-production inspection equipment and enabling real-time precision control.
Solution Approach 2:
The integrated measurement and control system provides continuous feedback during forming operations. Measurement data is immediately used to adjust forming parameters, preventing drift outside the tolerance window and maintaining manufacturing precision throughout production without requiring complex post-processing inspection equipment.
4Measurement precision
If human operators perform quality checks, then quality monitoring is possible, but productivity is reduced due to rework and waste
Solution Approach 1:
The automated feedback control system continuously monitors conductor element dimensions and immediately adjusts forming parameters to keep production within tolerance specifications. This prevents the generation of defective parts that would require rework or discarding, thereby maintaining quality monitoring capability while eliminating productivity losses associated with manual inspection and corrective actions.
Solution Approach 2:
The system performs preliminary quality control during the forming process itself rather than after production. By measuring and adjusting parameters in real-time during manufacturing, the system prevents defects before they occur, eliminating the need for post-production rework and maximizing productivity while maintaining quality standards.
Data Source
AI summary
A system for controlling a machine for forming conductor elements of an inductive winding of a stator, which comprises:a 3D vision device which is configured to generate a 3D reconstruction of each conductor element produced by the forming machine; anda monitoring device which is operatively connected to the 3D vision device and operatively connectable to the forming machine;where the monitoring device comprises:a measurement analysis module which is configured to assess at least one monitored characteristic measure of conductor elements that are produced by the forming machine; anda parameter correction module which is configured to correct one or more parameters of forming instructions that are executed by the forming machine.