Stator Winding Loading Apparatus with Guide Track and Arbor

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Solution Overview

Problem

The complex process of inserting stator windings into a stator core of electrical machines is inefficient, requiring manual handling and multiple steps for each wire, which complicates manufacturing and increases production time.

Innovation Solution

An apparatus comprising an arbor member with slots and guide tracks that positions and loads stator winding segments into predetermined slots, allowing for simultaneous alignment and insertion of multiple wires, simplifying the loading process by using a guide track system to position and rotate the arbor member for efficient slot filling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual handling and multiple steps are used for each wire insertion, then precision of wire placement is maintained, but productivity is reduced and manufacturing time increases

Engineering Contradiction:

Improveproduction efficiencyVSAvoidcomplexity of loading process

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines multiple wire insertion operations into a single integrated apparatus. The arbor member with multiple slots and guide tracks allows simultaneous positioning and insertion of multiple stator windings into the stator core, merging what would otherwise be separate manual operations into one coordinated process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The apparatus performs preliminary positioning of stator windings in the slots of the arbor member before insertion into the stator core. The guide tracks pre-align the windings, and the arbor member holds them in predetermined positions, preparing everything for simultaneous insertion into the core slots.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If individual wire insertion is performed manually, then ease of operation is maintained, but loss of time increases and productivity decreases

Engineering Contradiction:

Improvemanufacturing speedVSAvoidproduction time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The apparatus enables continuous operation by allowing multiple windings to be positioned and inserted simultaneously rather than sequentially. The coordinated movement of the arbor member and guide tracks ensures that all insertion actions occur in one continuous motion, eliminating idle time between individual wire insertions.

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If multiple separate operations are used for wire loading, then precision of slot alignment is achieved, but device complexity increases and ease of manufacture decreases

Engineering Contradiction:

Improveslot alignment precisionVSAvoidease of winding loading

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The arbor member serves multiple functions: it holds multiple stator windings in its slots, positions them precisely through the guide tracks, and transfers them simultaneously to the stator core. This multi-functional design eliminates the need for separate positioning and insertion operations, simplifying the manufacturing process while maintaining precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS8291577B2Apparatus for loading stator windings into a stator core

Publication Date: 2012.10.23 BORGWARNER INC

AI summary

An apparatus for loading stator windings into a stator core includes an arbor member including a body having an outer diametric portion and a central axis. The outer diametric potion includes a plurality of slots. The apparatus also includes a guide track having a first end that extends to a second end through a slide portion. The first end is positioned adjacent the outer diametric portion of the arbor member. At least one of the guide track and the arbor member is selectively positionable to guide slot segment portions of a stator winding into predetermined ones of the plurality of slots.