Automatic Stator Wire Lead Routing Apparatus
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Solution Overview
Problem
The manual routing of coil windings in electric motors is time-consuming and error-prone, making large-scale manufacturing inefficient.
Innovation Solution
An automated apparatus with a base assembly, arbor, end effector, and controller that automatically routes wire leads on a stator by gripping, rotating, and positioning them to achieve desired angular relationships, reducing manual intervention and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual routing of wire leads is used, then flexibility and adaptability are maintained, but time consumption and error rate increase significantly
Solution Approach 1:
The wire lead routing system performs self-service through automated detection and routing. The system automatically detects wire leads, determines their positions, and routes them to target locations without requiring continuous manual intervention, thereby significantly improving routing speed while maintaining precision
Solution Approach 2:
The patent replaces manual mechanical routing operations with an automated system combining image processing technology and mechanical routing mechanisms. The controller uses image data to automatically control the routing mechanism, substituting human-operated mechanical systems with automated ones to increase productivity
2Productivity
If automated routing is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The routing apparatus is designed with multi-functionality to handle various wire lead routing tasks. The same apparatus can detect, position, and route different types of wire leads using a unified system, which improves productivity without proportionally increasing device complexity through specialized components for each function
Solution Approach 2:
The patent introduces an image processing system as an intermediary between the wire leads and the routing mechanism. This intermediary captures image data, processes it to determine wire lead positions, and provides control information to the routing mechanism, enabling automated routing while keeping the overall system architecture manageable
3Manufacturing precision
If manual manipulation is used, then device complexity remains low, but manufacturing precision and error rate are affected
Solution Approach 1:
The system implements feedback through image processing that continuously monitors wire lead positions and provides real-time control information to the routing mechanism. This feedback loop ensures high routing accuracy by automatically adjusting based on detected positions, while the automated nature of the feedback process prevents time loss associated with manual inspection and adjustment
Data Source
AI summary
An apparatus for automatically routing a wire lead of a stator from a first position to a second position includes a base assembly to receive the stator. A clamp assembly is mounted on the base assembly to hold the wire lead in the first position. An arbor rotates the wire lead. The arbor has a holder to hold the wire lead. An end effector grips and moves the wire lead. A controller moves the end effector to grip the wire lead at the first position and to couple the wire lead with the arbor. Further, the controller rotates the arbor to rotate the wire lead along the circumference of the stator by a pre-determined angle. The controller moves the end effector to grip the wire lead held by the holder, and to move the wire lead to the second position.