Stator Lead Wire Bending Around Core Rib Interference
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Solution Overview
Problem
The existing stator manufacturing process is limited by the interference between the stator core ribs and the bending tools, which restricts the degree of freedom in designing the positions of lead wire segment coils.
Innovation Solution
A stator manufacturing device is introduced, featuring an abutment member that forms a bending start point for lead wire segment coils and a lead wire holding portion that is movable along the radial and axial directions of the stator core, allowing for flexible bending of the lead wire segment coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a punch and roller are used to bend the projecting portion of the lead wire segment coil, then the bending process can be performed, but the degree of freedom in designing the positions of lead wire segment coils is reduced due to interference with the ribs of the stator core
Solution Approach 1:
The lead wire holding portion is made movable along the radial direction and axial direction of the stator core with respect to the abutment member, allowing dynamic adjustment of the bending position to avoid interference with ribs while maintaining bending capability
Solution Approach 2:
The bending device is divided into two functional parts: an abutment member that forms the bending start point and a movable lead wire holding portion that applies bending force. This segmentation allows independent positioning of each component to accommodate rib locations
2Adaptability or versatility
If the lead wire holding portion is made movable along radial and axial directions, then the degree of freedom in designing positions is improved, but the device complexity increases
Solution Approach 1:
The lead wire holding portion is configured to be movable along the radial direction and axial direction of the stator core with respect to the abutment member within a range of existence of the stator core when viewed in the axial direction, enabling flexible positioning without requiring complex multi-axis mechanisms
Solution Approach 2:
The lead wire holding portion serves multiple functions: it holds the lead wire segment coil, provides bending force, and enables positioning in both radial and axial directions through a single integrated movable structure
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 solution enhances the degree of freedom in designing the positions of lead wire segment coils, enabling a more compact stator design and reducing manufacturing costs by allowing the use of a common cap for both lead wire and general wire segment coils.
Implementation Method 1
the projecting portion of the lead wire segment coil can be bent by moving the lead wire holding portion relative to the abutment member
Data Source
AI summary
A stator manufacturing device includes: an abutment member configured to form a bending start point in a lead wire segment coil among a plurality of segment coils inserted into a slot of a stator core, wherein the abutment member is configured to abut on a side surface of a projecting portion protruding from the slot of the lead wire segment coil from the outside in the radial direction of the stator core to form the bending start point; and a lead wire holding portion for holding the projecting portion of the lead wire segment coil, wherein the lead wire holding portion is configured to be movable along the radial direction and the axial direction of the stator core with respect to the abutment member.