Stator Manufacturing Device Radial Bending Mechanism
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Solution Overview
Problem
Conventional stator manufacturing techniques require multiple bending jigs for different conductor layers, limiting versatility and making it impossible to adjust the spacing between extension portions in the radial direction, leading to increased costs and reduced productivity.
Innovation Solution
A stator manufacturing device with an engagement portion that can be driven in the radial and circumferential directions, allowing for bending of extension portions at various radial positions using a single engagement portion, and an axial direction drive to maintain positional relationships, enabling bending with greater radial twist and accommodating different stator configurations without changing device components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple bending jigs are used for different conductor layers, then each layer can be bent at its specific radial position, but the device complexity increases and versatility decreases
Solution Approach 1:
The patent applies universality by designing a single bending jig that can perform multiple functions by adjusting its radial position. The bending jig includes a positioning mechanism that allows it to be moved radially to engage with extension portions at different radial positions corresponding to different conductor layers. This eliminates the need for multiple separate bending jigs while maintaining the capability to bend each layer at its specific radial position, thus resolving the contradiction between manufacturing precision and device complexity
Solution Approach 2:
The patent applies dynamics by making the bending jig movable in the radial direction rather than fixed. The bending jig is equipped with a radial positioning mechanism that enables it to dynamically adjust its position to match the radial positions of extension portions of different conductor layers. This dynamic capability allows one bending jig to replace multiple static jigs, reducing device complexity while preserving manufacturing precision for each layer
2Ease of manufacture
If the jig diameter is uniform, then the structure is simple, but it is impossible to bend extension portions while adjusting spacing between adjacent extension portions in the radial direction
Solution Approach 1:
The patent applies dynamics by enabling the bending jig to move radially, which dynamically adjusts the spacing between adjacent extension portions during the bending process. The radial positioning mechanism allows the bending jig to engage with extension portions at different radial positions, effectively adjusting the spacing between them. This maintains structural simplicity of the jig itself while providing high adaptability for different spacing requirements through positional adjustment rather than structural modification
3Device complexity
If a single engagement portion is used for all radial positions, then device complexity is reduced, but it cannot engage with extension portions at different radial positions without radial movement capability
Solution Approach 1:
The patent applies dynamics by equipping the single engagement portion with radial movement capability. The engagement portion is integrated with a radial positioning mechanism that allows it to move in the radial direction to engage with extension portions at different radial positions corresponding to different conductor layers. This dynamic positioning capability enables one engagement portion to replace multiple fixed engagement portions, reducing device complexity while maintaining full adaptability to engage extension portions at any required radial position
Data Source
AI summary
A highly versatile stator manufacturing device is provided. A stator manufacturing device 7 includes: an engagement portion 8 engageable with a distal end of an extension portion 5 of each of a plurality of conductor segments 4 extending from a plurality of extension positions that differ in a radial direction R in each slot 3 of a stator core 2; a circumferential direction drive portion 9 that drives the engagement portion 8 engaging with the extension portion 5 in a circumferential direction C, to bend the extension portion 5; and a radial direction drive portion 10 that drives the engagement portion 8 in the radial direction R.