Stator Pole Segment Assembly Automation
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Solution Overview
Problem
Existing stator production lines from pole segments lack automation, leading to inefficiencies in assembly, positioning accuracy, and increased costs due to the need for multiple general-purpose robots, with a high risk of disjoining or incorrect positioning during subsequent work stages.
Innovation Solution
An apparatus and method for accurately positioning and transferring pole segments using a transfer device with engagement members, clamping mechanisms, and a lead support system, which maintains alignment and secure positioning throughout the assembly process, reducing the need for extensive manual intervention and robot usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If general purpose robots are used for assembling pole segments, then automation level increases, but device complexity and cost increase significantly
Solution Approach 1:
The apparatus segments the assembly process into distinct functional zones: a first robot handles pole segment positioning and initial assembly, while a second robot performs subsequent operations like lead connection and terminal attachment. This division allows each robot to be specialized for specific tasks, reducing the need for complex general-purpose robots while maintaining high automation levels.
Solution Approach 2:
The apparatus creates a multi-functional assembly system where two standardized robots work in coordination on a shared platform. The first robot performs positioning and assembly functions, while the second robot handles electrical connections and terminal work. This multi-functional approach achieves high automation without requiring overly complex individual robots, as each unit has a defined specialized role.
2Adaptability or versatility
If pole segments are assembled in a non-final joining situation, then flexibility for subsequent operations is maintained, but reliability decreases due to high risk of disjoining or incorrect positioning
Solution Approach 1:
The first robot performs preliminary positioning and assembly of pole segments before final joining operations. The apparatus establishes initial alignment and temporary fixation, ensuring correct positioning is achieved before subsequent operations like lead connection and terminal attachment. This preliminary action prevents disjoining and positioning errors during later stages.
Solution Approach 2:
The apparatus maintains continuous engagement of pole segments throughout the assembly process. The first robot ensures continuous positioning and alignment, while the second robot performs operations without disrupting the established configuration. This continuous useful action prevents interruptions that could lead to disjoining or positioning errors, maintaining both reliability and flexibility.
3Productivity
If multiple general purpose robots work in parallel, then productivity increases, but device complexity and production space requirements increase
Solution Approach 1:
The production process is segmented into two main operational phases: assembly positioning (first robot) and electrical connection (second robot). This segmentation allows two robots to work in parallel on the same stator assembly, effectively doubling productivity without requiring a complete separate assembly line for each operation. The divided functional responsibilities reduce overall system complexity compared to using multiple general-purpose robots.
Solution Approach 2:
The apparatus merges assembly and electrical connection operations into a single integrated workstation. Two specialized robots share a common platform and work on the same assembly simultaneously, combining previously separate processes into one coordinated system. This merging increases productivity by eliminating transfer time between stations while reducing the total number of devices needed compared to fully separate assembly lines.
4Manufacturing precision
If specialized apparatus for pole segment assembly is developed, then manufacturing precision and positioning accuracy improve, but device complexity increases
Solution Approach 1:
The apparatus uses standardized, commercially available robots with universal interfaces and control systems. These multi-functional robotic units can perform various tasks through programming and tool changes, providing high positioning accuracy without requiring custom-built specialized equipment. The first robot handles positioning with precision, while the second robot performs electrical operations, achieving manufacturing precision through software control rather than mechanical complexity.
Data Source
Figure 1
Figure 2~2a
Figure 3
AI summary
An apparatus and method for manufacturing stators of dynamoelectric machines, the stators being formed as an assembly of pole segments (11); the apparatus comprising a seat (12) where the assembly of pole segments are seated. An engagement assembly (250) engages first ends (10d) of the pole segments for translation of the pole segments from the seat (12) to a transfer device (200). A first holding assembly comprises a first plurality of holding members (201,202,203) for clamping the pole segments to hold the pole segments as an assembly of pole segments. The first holding assembly being arranged on the transfer device (200)and the transfer device being moveable to transfer the assembly of pole segments from a first position (A) to a second position (B). A casing assembly (300) is located at the second position (B) and the casing assembly (300) being provided with a second plurality of holding members (311,312) for holding the assembly of pole segments. The second plurality of holding members are positioned on the casing assembly (300) to surround the assembly of pole segments that are located at the casing assembly (330).