Stator Slot Deburring Gauge With Abrasive Measurement Inserts
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Solution Overview
Problem
The existing manual process for removing burrs from the slots of a stator in electric motor manufacturing is inefficient and lacks precision.
Innovation Solution
A deburring gauge system comprising a gauge set with abrasive portions, a gauge holder, and a controller that automates the insertion and removal of the gauge set into the stator slots for effective deburring and measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a manual process is used to remove burrs from stator slots, then the process is simple to implement, but the productivity is low and manufacturing precision is poor
Solution Approach 1:
The gauge set is divided into multiple individual gauge parts, each designed to fit specific slot dimensions. This segmentation allows the system to handle different slot sizes efficiently while maintaining a modular structure that improves productivity without excessive complexity.
Solution Approach 2:
The automated deburring gauge system serves multiple functions: it measures slot dimensions, identifies burrs, and performs deburring operations. This multi-functionality consolidates what would otherwise require separate manual operations into a single automated system, significantly improving productivity.
2Manufacturing precision
If a manual process is used to remove burrs from stator slots, then the device complexity is low, but the manufacturing precision is insufficient
Solution Approach 1:
The gauge parts are pre-configured with specific cross-sectional shapes that correspond to predetermined slot dimensions. This preliminary preparation ensures that when the gauge is inserted into the slot, it automatically provides precise measurement and deburring according to the required specifications, achieving high manufacturing precision.
Solution Approach 2:
The system replaces manual mechanical deburring with an automated mechanical system controlled by a controller. The controller coordinates the movement and positioning of gauge parts, providing consistent and precise deburring operations that exceed manual capability while maintaining manageable system complexity through automated control.
3Productivity
If manual burr removal is used, then the ease of operation is high, but the productivity is low
Solution Approach 1:
The gauge system is designed to automatically perform measurement and deburring operations without requiring complex manual manipulation. The controller manages the entire process, and the gauge parts are self-contained with abrasive portions that automatically contact and deburr the slots upon insertion, simplifying operation while maximizing productivity.
Solution Approach 2:
The system incorporates movable gauge parts that can be dynamically positioned and moved through the slots by the controller. This dynamic capability allows the system to adapt to different slot configurations and perform multiple operations efficiently, improving productivity while the automated control maintains ease of operation.
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
The deburring gauge system enhances efficiency and precision in removing burrs and measuring slot dimensions, reducing manual labor and improving manufacturing consistency.
Implementation Method 1
The first body of each first gauge part includes an abrasive portion extending along a length of the first body
Data Source
AI summary
A deburring gauge system that includes a gauge set, a gauge holder secured to the gauge set, and a controller. The gauge set is configured to be at least partially inserted into a slot set of a stator. Each gauge part of the gauge set includes a body having a shape that corresponds to a shape of a respective slot of the slot set. The body of each gauge part includes an abrasive portion extending along a length of the body. The controller is in communication with the gauge holder and configured to move the gauge holder in a first direction toward the stator so that the abrasive portion of the body is at least partially inserted into the respective slot and move the gauge holder in a second direction away from the stator so that the abrasive portion of the body is removed from the respective slot.