Stator Winding End Twisting for Precise Welding and Insulation
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Solution Overview
Problem
Existing twisting devices for electric machine conductors on the welding side are prone to complications such as precise welding difficulties, electrical arcs, misalignment, and inability to insert insulating rings due to the proximity of conductor ends, making the welding process complex and risky.
Innovation Solution
An apparatus and process that utilize a twisting matrix with gripping elements and a radial actuator to deform conductor ends, allowing for easier welding, alignment, and insertion of insulating rings by separating and distancing terminals, facilitating automation and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conductor ends are kept close together for compact winding assembly, then space utilization is improved, but welding precision deteriorates and electrical arcs increase
Solution Approach 1:
The conductor assembly is segmented into distinct functional zones: the compact winding body maintains space efficiency, while the header portion is separated and extended to provide adequate workspace for welding operations. This segmentation allows the welding area to be spatially detached from the compact winding assembly, resolving the contradiction between compactness and welding precision.
Solution Approach 2:
The header portion is extended in the axial dimension perpendicular to the winding plane, allowing conductor ends to be positioned in a different spatial dimension for welding. This dimensional transition enables welding operations to occur at a distance from the compact winding assembly, improving welding precision without compromising volume efficiency.
2Volume of moving object
If conductor ends are positioned close together, then space efficiency is improved, but insertion of insulating rings becomes impossible
Solution Approach 1:
The conductor structure is divided into the winding portion and the extended header portion. This segmentation creates a dedicated space in the header region where insulating rings can be inserted without interfering with the compact winding assembly, thus maintaining space efficiency while enabling insulation operations.
Solution Approach 2:
The header portion is pre-formed with sufficient length and appropriate geometry before final assembly. This preliminary action creates the necessary space and accessibility for inserting insulating rings during the welding preparation stage, ensuring that insulation can be performed without compromising the compactness of the overall assembly.
3Productivity
If conductor ends are kept close for compact assembly, then productivity is improved, but safety deteriorates due to increased electrical arcs
Solution Approach 1:
The conductor assembly is segmented into the compact winding body and the extended header portion. This segmentation spatially separates the high-productivity winding assembly from the welding operations, allowing compact assembly for productivity while the extended header provides safe distance for welding, reducing electrical arc hazards.
Solution Approach 2:
The extended header portion acts as an intermediary element between the compact winding assembly and the welding zone. It provides the necessary spatial buffer that reduces electrical arc risks during welding operations while maintaining the productivity benefits of the compact winding structure.
4Device complexity
If conductor ends are positioned close together, then device simplicity is improved, but alignment precision deteriorates
Solution Approach 1:
The conductor structure is segmented into the simple compact winding body and the extended header portion. This segmentation maintains the simplicity of the overall device while the extended header provides the necessary alignment space and reference features for precise positioning during welding operations.
Solution Approach 2:
The header extension transitions the conductor ends to a different spatial dimension, providing adequate distance and angular access for alignment operations. This dimensional change enables precise alignment without requiring complex positioning devices, as the extended header itself serves as the alignment reference.
Data Source
AI summary
An apparatus for deforming conductors of at least one winding assembly, protruding from a side of a stator or of a rotor of an electric machine. The at least one winding assembly comprises a plurality of conductors comprising at least one leg inserted into cavities of stator or rotor, each having at least one respective free or terminal end. The apparatus comprises at least one twisting matrix adapted to rotate about an axis (X), comprising at least one gripping element adapted to grip at least one free end and adapted to be moved in radial direction with respect to said axis. The apparatus comprises at least one guide adapted to guide the at least one gripping element along the radial direction with respect to the axis; and a radial actuator, adapted to put in motion the at least one gripping element along the radial direction with respect to the axis.