SYSTEM AND METHOD FOR INSERTING WIRE INTO STATOR CORE OF AC GENERATOR

• US 20190319519A1
• Filed: 04/01/2019
• Published: 10/17/2019
• Est. Priority Date: 04/13/2018
• Status: Active Application

• Current Assignee: Victory Industrial Corporation
• Original Assignee: Victory Industrial Corporation
• Inventors: WANG, Chun-Yuan, KUAN, Yu-Tang
• Application Number:
  US16/372,162
• Publication Number:
  US 20190319519A1
• Time in Patent Office: Days
• CPC Class Codes: H01R 43/28 for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26
• CPC Class Codes: H02K 1/16 Stator cores with slots for windings
• CPC Class Codes: H02K 15/0018 Applying slot closure means in the core; Manufacture of slot closure means
• CPC Class Codes: H02K 15/0478 Wave windings, undulated windings when on diagonally wound hollow coils H02K15/0492
• CPC Class Codes: H02K 15/065 Windings consisting of complete sections, e.g. coils, waves windings for large electric machines other than those consisting of cables H02K15/063
• CPC Class Codes: H02K 15/066 inserted perpendicularly to the axis of the slots or inter-polar channels
• CPC Class Codes: H02K 15/067 inserted in parallel to the axis of the slots or inter-polar channels
• CPC Class Codes: H02K 15/085 by laying conductors into slotted stators
• CPC Class Codes: H02K 15/10 Applying solid insulation to windings, stators or rotors
• CPC Class Codes: H02K 3/12 arranged in slots
• CPC Class Codes: H02K 3/345 between conductor and core, e.g. slot insulation
• CPC Class Codes: H02K 3/50 Fastening of winding heads, equalising connectors, or connections thereto

Abstract

The present disclosure provides a system and a method for inserting a wire having a wavy shape into a stator core. The system includes a rotating receiver, a confining component, an expanding component and a pressing component. The rotating receiver is for rotating around an axis and receiving the wire. The rotating receiver includes multiple slots circumferentially disposed thereon. The slots extend along the axis. The confining component is for confining two adjacent linear segments of the wire separate within a space defined by the confining component. The expanding component is for adjusting the two adjacent linear segments so that they are separated from each other by a predetermined interval inside the space. The pressing component is for pressing the two linear segments into two of the multiple slots.

Claims

1. A system for inserting a wire having a wavy shape into a stator core, the system comprising:

a rotating receiver for rotating around an axis and receiving the wire, the rotating receiver including a plurality of slots circumferentially disposed thereon, the plurality of slots extending along the axis;

a confining component for confining at least two adjacent linear segments of the wire separate within a space defined by the confining component;

an expanding component for adjusting the two adjacent linear segments so that they are separated from each other by a predetermined interval inside the space; and

a pressing component for pressing the two linear segments into two of the plurality of slots.

2. The system of claim 1, wherein the confining component comprises:

two walls, which are separated from each other by a fixed distance; and

a first actuator configured to move the two walls to confine the two linear segments within the space defined by the two walls

3. The system of claim 1, wherein the expanding component comprises:

two expanding plates, which are generally parallel to each other; and

a second actuator configured to move the two expanding plates to adjust the distance between the two adjacent linear segments.

4. The system of claim 3, wherein the expanding component further comprises:

a pin disposed between the two confining plates and configured to be detachably inserted into a slot between the two slots to be inserted by the two linear segments.

5. The system of claim 1, wherein each of the two linear segments is held between one of the two walls and one of the two expanding plates, when the confining component and the expanding component are actuated.

6. The system of claim 1, further comprising:

an adjusting component for adjusting the height of the two linear segments to a predetermined height corresponding to the height of the two slots.

7. The system of claim 6, wherein the adjusting component comprises:

a pivoting portion with a first end pivotally connected to a support and a second end,

a rod disposed on the pivoting portion; and

a third actuator connected to the second end and configured to drive he pivoting portion to pivot about the first end so that the rod raises a curved segmentcurved segment of the wire that connects the two adjacent linear segments.

8. The system of claim 7, wherein the expanding component is provided on the pivoting portion of the adjusting component.

9. The system of claim 1, wherein the wire is defined as a first portion and a second portion that extend in two different directions, respectively, the first portion is inserted into the plurality of slots when the rotating receiver rotates in a first rotating direction, and the second portion is inserted into the plurality of slots when the rotating receiver rotates in a second rotating direction.

10. The system of claim 9, further comprising:

a rotating component for rotating the second portion of the wire so that the second portion of the wire is aligned with the first portion of the wire.

11. The system of claim 9, further comprising:

a first rail for bearing the first portion of the wire; and

a second rail for bearing the second portion of the wire;

wherein the first rail and the second rail are disposed near two opposing sides of the rotating receiver, respectively.

12. The system of claim 11, further comprising:

a pushing component for pushing the wire on the first rail towards the rotating receiver.

13. The system of claim 11, further comprising:

a lifting component for lifting the second rail, the lifting component being configured to move upward or downward; and

a moving component for moving the second rail towards or away from the rotating receiver;

wherein the moving component is disposed on the lifting component.

14. The system of claim 1, wherein the rotating receiver further comprises:

a disk including the plurality of slots; and

a cylinder passing through a through hole of the disk and supporting the disk.

15. The system of claim 14, further comprising:

a holding component detachably holding a free end of the cylinder.

16. The system of claim 14, further comprising:

a lid detachably disposed on a free end the cylinder for housing a stator core corresponding to the disk,

wherein the rotating receiver further comprises an extruding mechanism that has extruding components movable along the plurality of slots to extrude the wire to the corresponding slots of the stator core.

17. The system of claim 1, further comprising:

two blocks disposed on two sides of the confining component and extending towards the rotating receiver for covering the gaps between the confining component and the rotating receiver at the two sides of the confining component.

18. A method for inserting a wire having a wavy shape into a stator core, the method comprising:

moving the wire to a side of a rotating receiver having a plurality of slots so that two adjacent linear segments of the wire correspond to two of the plurality of slots;

adjusting the distance between the two linear segments so that they are separated by a predetermined interval;

inserting the two linear segments into the two slots of the rotating receiver; and

rotating the rotating receiver in a first rotating direction so that another two adjacent linear segments of the wire correspond to other two of the plurality of slots.

19. The method of claim 18, wherein the step of adjusting the distance between the two linear segments comprises:

confining the two linear segments within a space defined by two walls of a confining component; and

expanding the two linear segments by an expanding component having two expanding plates so that each of the two linear segments is hold between one of the two walls of the confining component and one of the two expanding plates..

20. The method of claim 18, wherein the wire is defined as a first portion and a second portion that extend in two different directions, respectively, the method further comprising:

rotating the rotating receiver in a second rotating direction; and

inserting two linear segments of the second portion of the wire into two corresponding slots of the rotating receiver.

21. The method of claim 18, before the step of inserting the two linear segments into two of the plurality of slots, further comprising:

adjusting the two linear segments to a predetermined height;

22. The method of claim 18, further comprising:

extruding the wire, from the plurality of slots, into the corresponding slots of the stator core.

23. A method for inserting a first wire having a wavy shape and a second wire having a wavy shape into a stator core, the method comprising:

moving the first wire to a side of a rotating receiver having a plurality of slots so that two first adjacent linear segments of a first portion of the first wire correspond to a first slot and a second slot of the plurality of slots;

adjusting the distance between the two first linear segments so that they are separated by a predetermined interval;

inserting the two first adjacent linear segments into the first slot and the second slot simultaneously;

rotating the rotating receiver in a first rotating direction so that next two first linear segments of the first wire correspond to a third slot and a fourth slot of the plurality of slots;

moving the second wire to the side of the rotating receiver so that two second linear segments of a second portion of the second wire correspond to a fifth slot and a sixth slot of the plurality of slots;

adjusting the distance between the two second linear segments so that they are separated by the predetermined interval;

inserting the two second adjacent linear segments into the fifth slot and the sixth slot of the plurality of slots; and

rotating the rotating receiver in the first rotating direction so that next two second linear segments of the second wire correspond to a seventh slot and an eighth slot of the plurality of slots.

24. The method of claim 23, further comprising:

moving a third portion of the first wire to the opposing side of the rotating receiver so that two third linear segments of the third portion of the first wire correspond to the first slot and the second slot;

adjusting the distance between the two third linear segments so that they are separated by the predetermined interval;

inserting the two third linear segments into the first slot and the second slot;

rotating the rotating receiver in a second rotating direction so that next two third linear segments of the first wire correspond to the third slot and the fourth slot;

moving a fourth portion of the second to the opposing side of the rotating receiver so that two fourth linear segments of the fourth portion of the second wire correspond to the fifth slot and the sixth slot;

adjusting the distance between the two fourth linear segments so that they are separated by the predetermined interval;

inserting the two fourth linear segments into the fifth slot and the sixth slot; and

rotating the rotating receiver in the second rotating direction so that next two fourth linear segments of the second wire correspond to the seventh slot and the eighth slot;

wherein the first rotating direction is opposite to the second rotating direction.