Stator Manufacturing Jig for Induction Heating and Resin Coating
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Solution Overview
Problem
Conventional stator manufacturing methods face complications due to magnetic levitation of steel plates during induction heating and adherence of resin to fastening holes, requiring complex operation steps and potential thermal deformation.
Innovation Solution
A method involving the use of holding members that cover fastening holes and the vicinity from above, preventing magnetic levitation and resin adherence, with these members being attached, heated, and then removed after resin coating, and are designed to be divided and reusable, allowing for efficient operation and prevention of deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If induction heating is performed to heat the stator core, then the electrical conductors can be coated with resin, but magnetic levitation occurs causing steel plates to curve and overheat
Solution Approach 1:
A holding plate with weight is placed on the steel plates to counteract the magnetic levitation force during induction heating. The weight provides a downward force that prevents the steel plates from curving upward, maintaining their flatness while allowing the induction heating process to proceed effectively.
Solution Approach 2:
The holding plate acts as an intermediary between the magnetic field and the steel plates. It provides a nonmagnetic barrier that interrupts the magnetic field lines, preventing direct interaction between the magnetic field and the steel plates, thereby eliminating magnetic levitation while still allowing thermal conduction for heating.
2Reliability
If resin is applied to the stator core, then insulation processing is achieved, but resin adheres to fastening holes preventing proper fastening
Solution Approach 1:
The holding plate is divided into multiple segments corresponding to different regions of the stator core. Each segment can be independently positioned to cover specific fastening holes while allowing resin application in other areas. This segmentation enables selective masking of fastening holes without compromising the overall insulation processing.
Solution Approach 2:
The holding plate is installed on the stator core before resin application. This preliminary action pre-masks the fastening holes, preventing resin from adhering to them in the first place. This eliminates the need for post-resin cleaning operations and ensures fastening holes remain clean for proper fastening operations.
3Reliability
If holding plate and masking tape operations are performed separately, then magnetic levitation and resin adherence are prevented, but the number of operation steps increases
Solution Approach 1:
The holding plate integrates multiple functions into a single component: it serves as both the magnetic levitation prevention device (by providing weight and nonmagnetic barrier) and the masking device (by covering fastening holes). This merging eliminates the need for separate holding plate installation and masking tape application operations, reducing the total number of steps while maintaining all necessary protective functions.
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 effectively prevents magnetic levitation and resin adherence, simplifies the manufacturing process, and allows for the reuse of holding members, enhancing operational efficiency and preventing deformation during thermal expansion.
Implementation Method 1
the steel plates are affected by magnetic field lines produced at the time of heating, thus magnetic levitation occurs
Implementation Method 2
a heating step (for example, a heating step S3 which will be described later) of heating the stator core by induction heating
Implementation Method 3
an attachment step (for example, an attachment step S2 which will be described later) of attaching, to the stator core, holding members which cover the fastening holes and the vicinity thereof from above
Implementation Method 4
a removal step (for example, a removal step S5 which will be described later) of removing the holding members from the stator core after the coating step
Data Source
AI summary
A manufacturing jig for a stator, the stator including a substantially annular stator core and electrical conductors. The stator core is formed by stacking, in layers, a plurality of thin plates where a plurality of fastening holes are formed in a vicinity of a circumferential edge portion so that the fastening holes are aligned in the stacking direction. The electrical conductors are partially inserted into a plurality of slots formed in the stator core. The manufacturing jig is attached to the stator core when a powder resin is applied to the electrical conductors and includes hole portions. The hole portions are arranged being divided in a circumferential by being divided in a circumferential direction of the stator core, cover the fastening holes and a vicinity thereof from above, and are formed so as to be able to be fastened to the fastening holes of the stator core.