Stator Assembly Preload Fixture for E-Charger Manufacturing
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Solution Overview
Problem
Conventional manufacturing methods for stator assemblies in rotary systems, such as e-chargers, are inefficient and labor-intensive, often requiring manual steps that hinder manufacturability and accuracy.
Innovation Solution
A method and system that progressively assemble the stator assembly from various parts, using a fixture to apply a preload and automate the attachment of teeth and windings, enabling efficient and accurate construction of the stator assembly within an e-charger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional manufacturing methods are used for stator assembly, then manual operations can be performed, but productivity is low and manufacturing efficiency is poor
Solution Approach 1:
The stator assembly process is divided into distinct modular stages: tooth attachment to inner support, winding attachment to teeth, and outer support attachment. Each stage is independently automated, enabling high-volume production while maintaining precision. The segmentation allows parallel processing and reduces cycle time.
Solution Approach 2:
Manual mechanical operations are replaced with automated attachment systems that use controlled mechanical forces. The system employs automated fixtures and positioning mechanisms to attach teeth, windings, and supports without manual intervention, significantly improving productivity and consistency.
2Manufacturing precision
If conventional manufacturing methods are used for stator assembly, then simple processes can be used, but manufacturing precision is poor
Solution Approach 1:
Teeth are pre-attached to the inner support with precise positioning before winding attachment. The fixture applies preload to establish accurate geometric relationships among components before final assembly, ensuring high manufacturing precision in the joint between inner support and teeth.
Solution Approach 2:
The system controls attachment parameters such as preload magnitude, application rate, and duration to optimize joint quality. By dynamically adjusting these parameters during the attachment process, the system achieves high precision while managing process complexity through automated control.
3Loss of time
If manual manufacturing steps are performed, then flexibility can be maintained, but time consumption increases
Solution Approach 1:
The automated attachment system operates continuously without interruption between stages. The fixture maintains preload throughout the attachment sequence, and components are transferred between stages without manual handling, eliminating idle time and significantly reducing total manufacturing time.
Solution Approach 2:
The fixture acts as an intermediary device that holds and positions multiple components (inner support, teeth, windings, outer support) during assembly. This intermediary mechanism enables rapid, coordinated attachment of all components without manual intervention, reducing manufacturing time while maintaining operational control.
Data Source
AI summary
A method of manufacturing a stator assembly for an electrified rotary system includes attaching a first tooth and a second tooth to an inner support to define a first construction. The first tooth and the second tooth extend radially away from the inner support in the first construction. The method also includes attaching a winding about the first tooth of the first construction to define a second construction. Furthermore, the method includes applying, with a fixture, a preload at a joint between the inner support and the first tooth of the second construction. Moreover, the method includes attaching an outer support to a first outer radial end of the first tooth and to a second outer radial end of the second tooth while applying the preload to define a third construction.