Rectangular Wire Coil Alignment Jig for Stable Leg Positioning
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Solution Overview
Problem
Existing rectangular wire coil alignment devices struggle to stabilize the posture of segment coils during stator manufacturing due to housing grooves that accommodate multiple leg portions, leading to instability.
Innovation Solution
A rectangular wire coil alignment device with a rotating alignment jig featuring penetration and groove portions that support and guide leg portions, allowing for stable alignment of rectangular wire coils by rotating them relative to the jig, reducing the size of penetration portions and minimizing tilting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a housing groove is configured to accommodate two leg portions of segment coils, then the alignment device can handle multiple coils, but the posture of the segment coil becomes unstable
Solution Approach 1:
The housing groove is divided into two separate penetration portions, each accommodating one leg portion of a segment coil. This segmentation allows each leg portion to be independently supported and positioned, preventing the instability that occurs when both leg portions are housed in a single groove. The alignment device can still handle multiple coils by providing multiple such penetration portions around the circular perimeter.
2Ease of operation
If the penetration portion is made large to accommodate leg portions, then insertion is easier, but the posture of the rectangular wire coil becomes unstable
Solution Approach 1:
The penetration portions are designed with specific local geometric features including inclined surfaces that guide the leg portions during insertion, and curved inner peripheral faces that provide stable support. The local quality of these surfaces ensures easy insertion while maintaining stable coil posture, as the inclined surfaces facilitate insertion and the curved surfaces provide precise positioning and support.
3Productivity
If the alignment jig is designed to rotate for aligning multiple coils, then productivity increases, but controlling the rotation and maintaining precision becomes more difficult
Solution Approach 1:
The penetration portions and groove portions are pre-configured at precise angular intervals around the circular alignment jig. This preliminary positioning ensures that when the jig rotates to align multiple rectangular wire coils, each coil is automatically positioned with the required precision. The pre-established geometric relationships between the penetration portions maintain alignment accuracy during rotation.
Data Source
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AI summary
Plural groove portions (36) are formed at a portion at radial direction outer sides of penetration portions (34) of an alignment jig (20) that is provided at a rectangular wire coil alignment device (10). The groove portions (36) are respectively disposed at positions, with respect to predetermined penetration portions (34), at predetermined intervals toward another circumferential direction side from the predetermined penetration portions (34), and are open at radial direction outer sides thereof. Further, each groove portion (36) is capable of accommodating another leg portion (16A) of a rectangular wire coil (16), and is capable of restricting movement of the leg portion (16A) toward a radial direction inner side.