Pre-insertion Device for Stator Winding Assembly

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Solution Overview

Problem

Existing methods for pre-inserting conductor bars to form electromagnetic windings are complex, prone to deformation, and require excessive free space, leading to inefficiencies and risks of collision during the final plug-in segment.

Innovation Solution

A novel method and device that allow for the pre-insertion of U-shaped conductor bars to form a winding basket using a pre-plugging device with a guide mechanism, enabling the formation of a closed ring without complex movements, minimizing deformation risks, and eliminating the need for additional positioning and correction steps, while allowing for manual or automated operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional methods are used to form a closed winding ring by twisting and coiling conductor bars, then the winding structure can be formed, but the process becomes complex and prone to deformation of conductor bars

Engineering Contradiction:

Improvewinding formation processVSAvoidconductor bar deformation

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The conductor bars are pre-positioned in a pre-insertion receptacle to form an open annular winding structure before final assembly. The ends are arranged with a minimum radial distance to prevent collision during closing, allowing the ring to be closed without complex twisting or coiling operations that cause deformation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The winding formation process is divided into two distinct steps: first forming an open annular structure with spaced ends, then closing the ring by bringing ends together. This segmentation avoids the need for continuous twisting and coiling operations that deform conductor bars

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If conductor bars are arranged with generous space between them in a winding basket, then manipulation is easier, but the device size increases and compactness is reduced

Engineering Contradiction:

Improveconductor bar manipulationVSAvoidwinding basket size

Core Design Contradiction:

Ease of operationVSVolume of moving object

Solution Approach 1:

Conductor bars are pre-positioned with precise spacing in the receptacle before final assembly, eliminating the need for generous clearance during manipulation. The pre-arranged configuration allows compact design while maintaining ease of operation during the pre-insertion phase

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The conductor bars are arranged in an open annular configuration where the ends overlap in the radial direction but maintain minimum radial distance. This spatial arrangement allows compact positioning without requiring excessive lateral space for manipulation

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Productivity

If conductor bars are inserted without minimum radial distance between ends, then the winding ring can be closed completely, but collision between conductor bars occurs during the final insertion segment

Engineering Contradiction:

Improvewinding ring closing efficiencyVSAvoidconductor bar collision risk

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The ends of the conductor bars are pre-positioned with a minimum radial distance before the closing operation. This preliminary spacing prevents collision during the final insertion segment while allowing the ring to be completely closed in the second step

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The minimum radial distance between ends acts as a protective buffer that prevents harmful collisions during the ring-closing operation. This beforehand cushioning ensures reliable closing without damage to the conductor bars

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Manufacturing precision

If multiple positioning and correction steps are used to insert conductor bars into final position, then precise positioning is achieved, but the process complexity increases

Engineering Contradiction:

Improveconductor bar positioning accuracyVSAvoidpositioning and correction steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Conductor bars are pre-positioned in the correct configuration in the receptacle before final assembly. This preliminary positioning eliminates the need for multiple correction steps during insertion, achieving precise positioning with a single insertion operation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The complex positioning and correction operations are extracted from the insertion process. The conductor bars are pre-positioned separately in the receptacle, and then inserted as a complete configuration, eliminating the need for multiple positioning steps during the insertion phase

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentEP4138284A1Method and device for laying out a winding assembly

Publication Date: 2023.02.22 MIBA AUTOMATION SYST GES

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AI summary

The invention relates to a method and a device for pre-inserting a winding arrangement of an electromagnetic winding of a stator and/or rotor before inserting the winding arrangement into the stator lamination stack. U-shaped conductor bars are arranged to form a winding basket using a suitable pre-insertion holder 1. During the pre-insertion of the conductor bars, an open annular winding structure 2 is formed in a first step, wherein the two ends 34 of the open annular winding structure overlap radially in an overlap region 33, and in a second step a closed winding structure is formed by joining the two ends.