Stator Turn Insertion Tool with Segmented Support Lamellas
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Solution Overview
Problem
Existing tools for inserting turns in laminated cores of electric motor stators often result in intertwining of wires, leading to compression and breakage, especially when using aluminum instead of copper, due to dimensional relations and material properties, which complicates the fabrication process and increases costs.
Innovation Solution
A tool with supplementary support lamellas arranged on a base ring, specifically designed to prevent intertwining by ensuring turns are spaced apart and guided correctly into their grooves, using materials like steel, aluminum, or plastics with reduced surface roughness to prevent misinsertion and breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If turns are inserted into grooves of laminated core, then coils are formed for electric motor stators, but intertwining of wires occurs between vicinal turns especially at extreme portions
Solution Approach 1:
The insertion tool is divided into multiple support lamellas (first, second, third, and fourth lamellas) that are spatially separated and each responsible for supporting specific portions of turns. This segmentation prevents intertwining by providing dedicated support zones for turns from different grooves, particularly at the extreme portions where intertwining most commonly occurs.
Solution Approach 2:
The support lamellas act as intermediary elements between the turns and the grooves. These lamellas provide a stable support structure that maintains the spatial separation of turns during insertion, preventing direct contact and intertwining between vicinal turns while still enabling proper placement into grooves.
2Ease of manufacture
If aluminum is used instead of copper for turns, then production costs are reduced, but mechanical strength decreases making turns more prone to breakage
Solution Approach 1:
The support lamellas are positioned beforehand to provide cushioning support to the turns during the insertion process. This prevents excessive compression forces from being applied to the turns, particularly protecting the more fragile aluminum turns from breakage while enabling cost-effective material substitution.
3Reliability
If compression force is applied to insert turns into grooves, then turns are secured in position, but intertwined sections are forced towards wrong grooves causing breakage
Solution Approach 1:
Different support lamellas are positioned at specific locations to provide localized support where needed. The first and second lamellas support turns from one groove while the third and fourth lamellas support turns from an adjacent groove. This local quality approach ensures that compression forces are applied uniformly and correctly to each turn, preventing forced displacement into wrong grooves.
Data Source
Figure 1A~1C
Figure 2~3
Figure 4~5
AI summary
The present invention pertains to the field of motors and refers to a tool for inserting turns in laminated cores for fabrication of stators, said tool comprising technical, construction and structural aspects which promote and ensure suitable conduction of turns to the right grooves of said laminated cores of stators, thereby preventing the electric conductive wires from breaking during the process of inserting turns in the laminated core to form an electric motor coil. More specifically, said tool for inserting turns in laminated cores, in accordance with the present invention, comprises a plurality of support lamellas (11) disposed on a base ring (120) over which turn coils (E) are positioned, where at least the extreme support lamellas (11') are provided with a supplementary lamellas (130) disposed on said support lamellas (11,11').