Stator Manufacturing Suction Unit for Fragment Removal
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Solution Overview
Problem
During the manufacturing of stators by twisting and bending coil segments, fragments from chipped leading edges can interfere with insertion recesses, leading to conduction at insulated locations due to adherence between segments.
Innovation Solution
A stator manufacturing method and apparatus that includes rotating twisting and bending jigs with suction units to remove fragments from insertion recesses after segment insertion, ensuring insulation by preventing fragment adherence during subsequent twisting and bending operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the end of the first straight portion or the second straight portion is inserted into the insertion recess, then the coil segment can be twisted and bent, but the leading edge part may interfere with the opening location and generate fragments that enter inside the insertion recess
Solution Approach 1:
The suction unit extracts fragments from the insertion recess by applying negative pressure, removing the harmful fragments that entered during the twisting and bending operation. This extraction process prevents fragments from adhering to subsequent coil segments.
Solution Approach 2:
The suction unit acts as an intermediary mechanism between the insertion recess and the external environment, using air flow as a medium to transport fragments out of the recess without direct mechanical contact with the coil segments.
2Reliability
If fragments remain inside the insertion recesses, then they may become adhered to the segments to be twisted and bent, but this causes conduction at locations that should be insulated
Solution Approach 1:
The suction operation is performed after the twisting and bending is complete but before the next coil segment is inserted. This preliminary cleaning action removes fragments in advance, preventing them from adhering to subsequent segments and causing insulation failures.
Solution Approach 2:
The suction unit converts the potentially harmful presence of fragments into a beneficial cleaning process. By actively removing fragments that would otherwise cause insulation failures, the system transforms a harmful byproduct into an opportunity to ensure reliable insulation.
3Reliability
If a suction unit is added to remove fragments from insertion recesses, then insulation is maintained, but the device complexity increases
Solution Approach 1:
The suction unit is integrated into the existing twisting and bending apparatus, serving multiple functions: it cleans fragments from insertion recesses, prevents insulation failures, and can be operated using the same control system that manages the twisting and bending operations. This multi-functionality reduces the need for separate dedicated cleaning equipment.
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
Maintains insulation at intended locations by effectively removing fragments from insertion recesses, preventing unwanted electrical pathways and ensuring reliable stator assembly.
Implementation Method 1
simultaneously suctioning interiors of all of the insertion recesses
Data Source
AI summary
A stator manufacturing apparatus is equipped with spindles as twisting and bending jigs, an inner guide having a first supply flow path and a suction flow path formed in the interior thereof, and an outer guide having a second supply flow path formed in the interior thereof. Further, the spindles have receiving members in which insertion recesses are formed. Through holes are formed in the receiving members, and the receiving members are formed with lateral holes therein which allow the interiors of the insertion recesses to communicate with each other.