Wire Conductor Alignment Apparatus for Dynamo Electric Machine Stators
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Solution Overview
Problem
The existing technologies face challenges in accurately and efficiently aligning wire conductors in dynamo electric machines, particularly in adapting to variations in stator configurations, ensuring precise positioning without damaging the conductors, and reducing alignment time in high-production scenarios.
Innovation Solution
An apparatus and method utilizing a first and second alignment assembly with L-shaped extension arms and plates, actuated by a radial pushing assembly, to accurately position wire conductor ends on specific radii for welding, allowing for quick adaptation to different stator configurations and minimizing alignment stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional positioning solutions are used, then alignment can be performed, but the available space between conductor ends is insufficient and excessive straightening force damages insulation
Solution Approach 1:
The patent introduces a positioning element as an intermediary component between the positioning solution and the conductor ends. This positioning element features a curved surface that gently guides and positions the conductor ends without requiring excessive straightening force, thereby preventing insulation damage while achieving accurate alignment.
Solution Approach 2:
The patent modifies the geometric parameters of the positioning element, specifically incorporating a curved surface with optimized radius and angle. This parameter change allows the positioning element to accommodate the natural curvature of conductor ends, reducing the force needed for alignment and preventing insulation damage.
2Productivity
If welding operations are performed on various stator types, then production volume increases, but variations in stator configuration require frequent adaptation of positioning solutions
Solution Approach 1:
The patent designs the positioning element with universal characteristics that allow it to work with multiple stator configurations. The curved surface geometry and adjustable positioning mechanism enable the same positioning element to accommodate variations in conductor end positions across different stator types, eliminating the need for frequent tooling changes.
Solution Approach 2:
The patent incorporates dynamic adjustment capabilities in the positioning solution, allowing real-time modification of positioning parameters during welding operations. This dynamic adaptability enables the system to handle variations in stator configurations without stopping production for tooling changes.
3Manufacturing precision
If more time is allocated for alignment, then positioning accuracy improves, but production time increases and hourly output decreases
Solution Approach 1:
The patent implements preliminary positioning actions that pre-align conductor ends before the actual welding process. The curved surface of the positioning element performs initial guidance and rough alignment, reducing the time needed for final precision positioning and enabling faster overall alignment while maintaining accuracy.
Solution Approach 2:
The patent replaces complex mechanical alignment systems with a simpler curved surface positioning element. This substitution eliminates the need for time-consuming manual adjustments and complex mechanical mechanisms, achieving both high positioning accuracy and rapid alignment speed.
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
Enables high-accuracy, rapid alignment of wire conductors, preventing damage and accommodating various stator configurations, thereby improving the quality and efficiency of the welding process in dynamo electric machines.
Implementation Method 1
actuated by a radial pushing assembly, to accurately position wire conductor ends on specific radii
Data Source
AI summary
The apparatus and process relate to aligning ends of wire conductors extending from coil members inserted in slots of a core (10) of a dynamo electric machine to join the ends of at least two wire conductors (EP1, EP2, EP3, EP4, EP5) by means of a welding operation; wherein the ends to be joined are aligned along radiuses (R1, R2) of the core (10), and wherein spacing (S1, S2) exists between two adjacent radiuses (R1, R2) of the core (10). This apparatus and this process provide for a first alignment unit (120) to which the following steps are made to be performed: positioning a first member (25) in a first spacing (S1) existing on one side of a first radius (R1) of said core (10); positioning a first abutment portion (23′, 33′) at a first position situated radially between a first group of ends (EP1) to be joined and a second group of ends (E2) to be joined, said first and second group of ends being aligned along said first radius (R1); positioning a second member (35) in a second spacing (S2) existing on the opposite side of the first radius (R1); positioning a second abutment portion (33′, 23′) at a second position situated radially between said first group of ends (EP1) to be joined and said second group of ends (E2) to be joined; positioning a first pusher (41) at a radially outer position relative to said core (10) for pushing said first group of ends (EP1) to be joined against said first abutment portion (23′, 33′); positioning a second pusher (42) at a radially inner position relative to said core (10) for pushing said second group of ends (EP2) to be joined against said second abutment portion (33′, 23′); arranging first means (302, 308) configured for relatively moving the first member (25), the second member (35), the first abutment portion (23′, 33′) and the second abutment portion (33′, 23′) in an axial direction (Z, Z′) of the core (10); arranging second means (200) configured for relatively moving the first radial pusher (41) and the second radial pusher (42) in the radial direction (R, R′) of the core (10); arranging third means (100) configured for moving the first member (25) and the second member (35) one towards the other in a circumferential direction (CS, CS′) of the core (10).