Stator Resin Impregnation Rotation to Reduce Dripping Loss
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Solution Overview
Problem
Existing methods for manufacturing stators for rotary electric machines face challenges in efficiently reducing dripping of liquid resin material after the workpiece is lifted from the bath during the impregnation process.
Innovation Solution
A method involving a preparation step, immersion step, and rotation steps to orient and rotate the workpiece in specific postures to efficiently guide and drain the liquid resin material, including a rotation step to separate adhering resin from the workpiece and promote re-adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the workpiece is lifted vertically from the bath without rotation, then the impregnation target area is separated from the bath, but liquid resin material continues to drip from the workpiece
Solution Approach 1:
The workpiece is rotated about its central axis during the lifting process to dynamically change the orientation of the impregnation target area. This rotation causes the liquid resin material to drain back into the bath due to gravity, effectively reducing dripping losses while maintaining production efficiency
Solution Approach 2:
Instead of purely vertical lifting, the workpiece is rotated to change its orientation in space. The impregnation target area is oriented to face different directions during rotation, allowing gravity to act on the liquid resin material and cause it to drain back into the bath, thus solving the dripping problem
2Loss of substance
If the workpiece is rotated during immersion, then liquid resin material drains back into the bath reducing dripping, but the impregnation process becomes more complex
Solution Approach 1:
The rotating mechanism serves multiple functions: it orients the impregnation target area for proper resin coating, facilitates drainage of excess resin back into the bath, and can be integrated with the lifting mechanism. This multi-functionality reduces the need for separate drainage devices, thereby limiting the increase in device complexity
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 approach effectively reduces dripping and minimizes the amount of resin lost, shortens production time, and ensures efficient coverage of the impregnation target areas, thereby enhancing the manufacturing process efficiency.
Implementation Method 1
a rotation step for rotating, after the immersion step, the workpiece at a raised position of the workpiece where the impregnation target area is separated from the bath
Implementation Method 2
rotating the workpiece about a workpiece central axis corresponding to a stator central axis in a posture of the workpiece in which the impregnation target area is oriented in a direction intersecting a vertical direction
Data Source
AI summary
Provided is method for manufacturing a stator for a rotary electric machine. The method includes: preparing a workpiece in which a plurality of coil pieces forming a stator coil is attached to a stator core, the workpiece having tips of one of the coil pieces and another of the coil pieces joined together on one axial end side; immersing, after the preparation step, the workpiece in a bath of a liquid resin material so that an impregnation target area including a joint between the tips is immersed; and rotating, after the immersion step, the workpiece at a raised position of the workpiece where the impregnation target area is separated from the bath. The rotating step includes rotating the workpiece about a workpiece central axis corresponding to a stator central axis in a posture of the workpiece in which the impregnation target area is oriented in a direction intersecting a vertical direction.