Stator Winding Bending Tool for Oil Cooling Flow
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Solution Overview
Problem
The manual bending of conductive pins in stator windings of electric machines is difficult due to material elasticity, hindering effective oil circulation for cooling, as the arms' folds obstruct fluid passage and require precise bending to maintain reproducibility and efficient heat transfer.
Innovation Solution
A tool with a shaper of revolution is used to guide and orient the arms of conductive pins, ensuring a reproducible distance between the magnetic circuit and the folding of each arm, facilitating better oil circulation by maintaining alignment and orientation, and aiding in the formation of the bun shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If manual bending of pin arms is performed to create folds for oil circulation, then cooling efficiency is improved, but manufacturing precision and reproducibility deteriorate due to material elasticity
Solution Approach 1:
The patent applies preliminary action by pre-forming the pin arms with a predetermined geometry before insertion into the magnetic circuit. The arms are manufactured with a specific shape that includes a straight portion and a folded portion, eliminating the need for manual bending after insertion. This pre-formed geometry ensures consistent oil circulation channels while maintaining manufacturing precision through controlled production processes.
2Object-generated harmful factors
If arms are bent to extend in the extension of the notch for oil passage, then heat transfer fluid circulation is improved, but ease of operation deteriorates due to material elasticity
Solution Approach 1:
The pin arms are pre-formed with the required folded geometry before insertion into the notches. The folding is performed during manufacturing when the material can be easily shaped, and the folded portion is then inserted as a complete unit. This eliminates the difficulty of manual bending after insertion while ensuring proper oil passage geometry.
Solution Approach 2:
The patent applies local quality by creating a specific folded geometry at the free end of each pin arm, while the portion inserted into the magnetic circuit maintains a straight configuration. This localized folding at the terminal end provides the necessary oil circulation channels without compromising the structural integrity or electrical connection properties of the inserted portion.
3Manufacturing precision
If multiple pins are used to orient arms in determined directions, then manufacturing precision of winding shape is improved, but device complexity increases
Solution Approach 1:
The pin arms are pre-formed with the required folded geometry and orientation before insertion. This preliminary shaping eliminates the need for complex tooling with multiple pins to orient the arms during assembly. The pre-formed arms simply need to be inserted into the notches, significantly simplifying the assembly process while maintaining manufacturing precision.
Data Source
Figure 1
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AI summary
The invention concerns an equipment for producing coils of a stator of an electrical machine and method for making coils. The coil is formed by connecting arms (6) of conductive pins (4) inserted in slots (3) of a magnetic circuit (2) of the stator (1). The equipment comprises a conformator (10) revolving about an axis (5), the conformator (10) being designed to be placed inside the free ends of the arms (6) and pressed against the magnetic circuit (2), a series of driver pins (12) in equal number with the slots (3) and designed to penetrate each into a hole of the conformator (10), each hole being bored along an axis, the axes of the holes (10) being concurrent in a first point (14) of the axis of revolution (5) of the conformator (10), each driver pin (12) being designed to separate two arms (6) of pins (4) inserted into two adjacent slots (3) so as to direct the arms (6) in a specific direction, different from the direction of the arms (6) in their slot (3). The invention also concerns a method using such an equipment which consists in performing successively the following operations: inserting the pins (4) in accordance with a wiring layout of the coil; setting in place the first conformator (10) along the axis (5) of revolution of the magnetic circuit (2) on the free side of the arms (6) pressed against the magnetic circuit (2); placing the first series of driver pins (12); folding the arms (6) of each by pressing on a driver pin (12) of the first series.