Winding Forming Drum Alignment for Faster Stator Slot Insertion
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Solution Overview
Problem
Conventional production lines for electric machine stators face inefficiencies due to the use of anthropomorphic robots, which increase cycle times and costs, and Cartesian movement apparatuses, which lack the flexibility to adjust the position of conductive elements for precise alignment with slots.
Innovation Solution
An assembly for forming windings that includes a collection drum with radially extending seats and means for adjusting the drum's position and orientation, allowing for precise alignment of conductive elements with seats, even when using a Cartesian movement apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an anthropomorphic robot is used to pick and place conductive elements, then positioning flexibility and adaptability are improved, but cycle time increases and productivity decreases
Solution Approach 1:
The system is divided into two independent parts: a Cartesian movement apparatus for rapid positioning and a collection drum with adjustable seats for fine alignment. The gripper handles coarse positioning while the drum handles fine positioning, allowing each component to optimize its function without compromising the other.
Solution Approach 2:
The collection drum acts as an intermediary device between the Cartesian gripper and the final insertion point. It receives conductive elements from the gripper and provides the necessary positioning adjustments through its adjustable seats, mediating between the fast but inflexible gripper and the precision requirement.
2Productivity
If a Cartesian movement apparatus is used to pick and place conductive elements, then cycle time decreases and productivity increases, but positioning flexibility and alignment precision are reduced
Solution Approach 1:
The positioning function is segmented into two stages: coarse positioning by the Cartesian gripper (fast) and fine positioning by the adjustable drum seats (precise). This segmentation allows the system to benefit from both the speed of Cartesian movement and the flexibility of adjustable positioning.
Solution Approach 2:
The drum seats are made dynamically adjustable during the operation. The seats can be moved radially and rotated to accommodate variations in conductive element geometry and deformation, providing adaptability that complements the fixed Cartesian movement paths.
3Device complexity
If fixed coordinate positions are used in Cartesian movement apparatus, then control simplicity is improved, but ability to accommodate element deformations and achieve precise alignment is reduced
Solution Approach 1:
The collection drum with its adjustable seats performs the self-adjustment function. Instead of requiring complex control logic to calculate and compensate for element deformations, the drum seats automatically adapt to the actual position and orientation of each conductive element through their mechanical adjustability.
Data Source
AI summary
An assembly for forming windings for electric machines, comprising: a supporting frame, a collection drum which has a central axis of symmetry and is supported on a plane of arrangement of the frame wherein the drum has a plurality of seats arranged according to a predefined distribution; at least one grip element which is configured to pick up at least one electrically conductive element from a delivery station and to move the picked-up element up to the insertion at least of a portion of interest of the element in a seat of the drum.The assembly comprises means for translation which are configured to translate the drum on the plane of arrangement so as to vary the position of the central axis of the drum on the plane of arrangement.