Stator Winding Rigid Bar Connection Bridge Automation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The complexity and difficulty in automating the coupling of connection bridges to stator windings with rigid bars in electric machines, due to the need for manual adjustments to properly insert the ends of the legs into corresponding seats, hinder efficient production and increase the risk of mechanical interference and damage.
Innovation Solution
The configuration of 'U'-shaped rigid bars with specific folds allows for easy insertion into stator slots without further bending, enabling a single bending step and reducing mechanical interference, while connection bridges with plastically deformable seats simplify the coupling process, allowing for automated assembly and optimal electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection bridges are coupled to stator windings with rigid bars, then electrical connections are established, but the process becomes complex and difficult to automate requiring manual adjustments
Solution Approach 1:
The connection bridges are pre-assembled with the stator winding in a predetermined configuration before final assembly. The legs are pre-positioned in the stator slots and the connection bridges are pre-aligned with their corresponding seats, eliminating the need for complex manual adjustments during automated assembly.
Solution Approach 2:
The patent introduces an intermediate assembly step where the connection bridges are temporarily held in position by the stator winding structure itself during the coupling process. This intermediate state allows automated systems to establish connections without requiring complex adjustment mechanisms.
2Manufacturing precision
If manual adjustments are performed to insert legs into connection bridge seats, then proper insertion is achieved, but production efficiency decreases and automation becomes difficult
Solution Approach 1:
The stator winding structure itself serves as the positioning mechanism for the connection bridges. The legs and seats are designed to self-align and self-position during assembly, eliminating the need for operator intervention to achieve proper insertion. The predetermined configuration ensures that components find their correct positions automatically.
Solution Approach 2:
The patent modifies the geometric parameters of the legs and seats to enable easier automated insertion. The seats are designed with specific dimensional tolerances and orientations that accommodate automated insertion forces, while the legs are shaped to guide themselves into the correct position without manual adjustment.
3Ease of manufacture
If rigid bars are bent and inserted into stator slots, then stator winding is formed, but mechanical interference and damage risk increase
Solution Approach 1:
The rigid bars are pre-bent into the required configuration and pre-assembled into the stator slots before final assembly. This preliminary positioning allows the bars to be inserted in a controlled manner, reducing mechanical interference during the assembly process and minimizing the risk of damage to both the bars and the stator slots.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method simplifies the construction of stator windings by reducing manual intervention, minimizing mechanical interference, and ensuring robust and efficient electrical connections, thereby enhancing production efficiency and reducing the risk of damage to the stator winding components.
Implementation Method 1
connection bridges with plastically deformable seats simplify the coupling process, allowing for automated assembly and optimal electrical contact
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method to construct an electric machine (1) provided with: a stator (5) having a magnetic core (6) longitudinally crossed by a plurality of stator slots (7); a stator winding (8) having a series of rigid bars (9), which are "U"-shaped and are inserted through the stator slots (7) defining an entry side (12), in which the cusps (11) of the "U"-shaped bars (9) are placed, and an exit side (13), in which the legs (10) of the "U"-shaped bars (9) are placed; the construction method comprises the steps of electrically connecting the ends of at least two non-adjacent legs (10) to one another by means of a connection bridge (18; 28; 30; 32; 34), which is made of a flat plate arranged perpendicular to the central axis (3) of rotation and has, for each leg (10), a corresponding "U"-shaped seat (19), which is suited to receive the end of the leg (10).