Embedding Prefabricated Windings TRIZ Cases

By pre-bending an adjacent coil end to create an inclined base, stator power lines can be formed with simpler, more controlled bending.

Elongate channels let an aluminum motor casing expand evenly during press fitting, avoiding warping while preserving heat dissipation.

Radial engagement of segment coil leg tips improves alignment accuracy, reduces assembly defects, and speeds armature insertion.

Separated penetration and groove portions stabilize rectangular wire coil legs during jig rotation, improving stator alignment precision.

Manufacturing data is marked on bare coil ends, preserving insulation quality while enabling slot-level traceability in stator assembly.

Bulk HTS terminals and heated interconnect layers simplify superconducting tape joints while avoiding cleanroom-heavy oxygen reprocessing.

A magnetically stacked rotor-stator package simplifies axial flux machine transport, lowers contamination risk, and enables air-gap setup during installation.

A two-step stator coil insertion process limits adjacent insertion depth to avoid connecting-member contact, preserving coating and insulation.

Guide strips and staged pin transfer simplify rotary machine winding insertion while preventing enamel damage, mispositioning, and short-circuit risk.

Rotating feed and transfer stages place hairpin pins accurately, cutting misalignment, enamel damage, and assembly time in electric machines.

A staged pin insertion process creates alignment space without global twisting, reducing enamel damage, short circuits, and assembly cost.

Flat-positioned transverse strands guide axial wire pivoting in slots, preventing crossings and easing notch-closing wedge insertion.

A cylindrical cover and resin layer stabilize toothless armature windings, improve heat dissipation, and prevent leakage in rotary machines.

Offset connectors link layered shaped conductors into symmetric multi-path stator windings, cutting end overhang and easing automated assembly.

Preformed U-shaped wires are laterally inserted and welded on stator poles to raise copper fill and speed concentrated winding manufacture.

Segmented holding units move hairpin conductors along controlled paths to form flexible circular stator configurations with less tooling complexity.

Rotating containment slots and cam guides insert multiple I-pins into small-diameter windings without gripper interference, cutting cycle time.

Curved grouped interconnection pieces let rod conductors be pre-positioned and welded in compact planes, reducing stator height and connection losses.

Bent end sections link two winding layers so stator slot sections can shift radially, cutting winding thickness and insertion effort.

Overlapping segment facing surfaces and chamfered edges increase armature joint area while easing insertion and protecting insulation.

Independently movable pressing jigs apply uniform force to armature segment conductors despite height variation, improving joint quality.

A rotating ring tool positions stator conductor ends in final interlaced order, cutting winding head height and simplifying interconnection.

A segmented winding tool with movable end parts pulls layer windings into tapered stator slots with lower force, less insulation damage, and higher fill factor.

A rotary table with removable inserters aligns and calibrates hairpin conductors during stator winding insertion, cutting mechanism complexity and cycle time.

A linear stator transfer and guide approach simplifies BLDC coil winding, improves space use, and supports thicker coils with controlled tension.

Shaped hairpin contact regions form an added layer and direct strand connections, cutting jumper parts, assembly effort, and winding complexity.

Individually wound and cast coil bundles fit within the stator bore, boosting copper fill and enabling repairable downhole pump motors.

A separately cast coil pack is axially inserted into the stator to raise copper fill, shorten motor length, and simplify borehole pump repair.

Curved radial interconnection webs join stator bar conductors with less winding-head space, simpler assembly, and secure welded contacts.

Successive partial phase insertions reduce wire interference in rotor and stator slots, raising filling rate and lowering phase resistance.

Axial gripper insertion into a slotted assembly drum speeds hairpin winding assembly while improving positioning precision and reducing mechanism complexity.

An annular fixture and guiding device align and insert bar conductors with varied leg lengths and cross-sections without extra grippers.

A mixed wide- and narrow-pitch coil connection layout balances same-phase stator coils to suppress circulating currents and cut reactive power loss.

Inclined contact surfaces and continuous preformed winding sections raise stator slot fill while keeping motor winding production fast and low cost.

A blade widens slot insulation during coil insertion, preventing paper shift while cutting assembly time and extra insulating material.

Dual grip planes pre-position and hold rod-shaped coil elements for accurate core groove insertion with less material and fewer alignment steps.

Cam blocks and a containment ring pre-assemble non-circular hairpin windings without grippers, handling varied leg lengths and pitch.

A coil segment forming apparatus uses multiple jigs and drive mechanisms to bend wire rods into predetermined shapes without exchanging press dies.