Manufacturing Dynamo-Electric Machines TRIZ Cases

See how a motor-driven adjustable orifice plate enables remote fluid flow control in generators

Continuous winding on a nine-tooth stator uses paired crimp terminals to cut connection points, reducing motor assembly time and cost.

A restraining jig and robot-guided bending tool keep stator segment coils aligned axially, easing tooth insertion and final end forming.

A thicker radial joint section maintains pressing force at stator segment ends, preventing coil curvature and incomplete conductor joining.

Overlapping segment conductor faces with chamfers only at circumferential edges preserve joint area and stabilize armature connections.

Inclined U-pin weld portions and asymmetric winding factors cut torque ripple, AC Joule losses, and stator assembly complexity.

A three-zone insulated conductor enables laser baring with less dust, shorter cycle time, and lower short-circuit risk during motor winding welding.

Non-machined backing surfaces in a cast motor housing block blowhole leakage paths after machining, preserving sealing and cutting cost.

Intermediate rotor bearings keyed to the stator can improve ESP motor alignment, block fluid ingress, and simplify assembly.

Laser ablation strips laterally protruding wave-winding wire ends in defined windows, reducing contamination, access issues, and cycle time.

Separated lateral pressing and heating of core sheets prevents residual stress, limits iron loss, and improves laminated core adhesion.

A flinger seal, contact seal, and segmented housing improve motor ingress protection across mounting orientations while preserving service access.

Twisting only the rotor-end wire turns cuts coil losses while preserving coil shape and easier stator assembly.

When users push a powered door faster than its preset speed, the controller switches modes to assist motion and avoid surprising resistance.

Inserted wire ends are soldered inside a defined hardening space, simplifying motor coil connections while keeping joints reliable despite alignment variation.

Axial and circumferential jig movement bends stator tip portions of different lengths while protecting uninsulated coil ends from damage.

Separating room-temperature pressurization from adhesive-softening heat bonding lowers residual stress and keeps laminated core iron loss low.

D-axis AC turns the motor into a distributed heat source, boosting battery heating speed and uniformity during vehicle operation.

Radial pushers compact wire ends in core slots before twisting, reducing springback and preserving alignment for reliable welding.

A retainer and stand-off let engineers replace one failed interpole coil on an integral-core DC motor frame without full rewinding.

Mixed Nd- and Pr-rich core-shell grains raise coercivity while preserving residual flux density and reducing heavy rare earth use.

A six-step large-small slot winding layout balances phase conductors, cuts stray loss, and shortens stator half-turn length.

A rotor wedge uses a non-conductive central section and conductive wings to cut eddy current loss while maintaining heat transfer.

Shifting the welding jet from the joining area to the edge before shutoff cuts pore formation and improves hairpin stator weld quality.

Filled composite polymer replaces metal stator housings to cut motor production cost while preserving heat dissipation and mechanical integrity.

A softer plating layer deforms into micro-grooves at the stator coil fitting joint, improving conduction reliability and lowering contact resistance.

Radial pressure on stator slot cover slides during resin gelation compacts windings, removes voids, and improves dielectric strength and heat dissipation.

A deep-drawn, flow-formed can wall paired with a separate flange keeps the driver-rotor gap narrow while preserving mounting accuracy and reliability.

Injection molding secures the stator assembly and pin within the pump housing, simplifying assembly while improving sealing and structural integrity.

Direct hydraulic cooling around stator windings boosts power density while insulated connection elements preserve electrical isolation and simplify assembly.

An embedded oscillating heat pipe moves heat from stator windings to the housing, improving motor cooling without added mass or complexity.

Cam-driven cutting and counter-bearing slides scrape wire insulation at high speed with minimal contamination, supporting clean coil winding welds.

Integrated magnetic sensing enables closed-loop mirror angle control in folded camera modules, reducing module length without added sensing hardware.

Prefabricated wiring elements and laser welding simplify stator coil interconnection while keeping the motor assembly compact and stable.

A non-ferrous two-plate clamp grips linear motor actuator guide rails to counter magnetic attraction and prevent operator injury.

Screw thermoregulation and heated mold filling keep thermoset resin uniform, reducing motor core fill defects and resin waste.

Straight connection portions and segmented bends shrink axial winding space, simplify coil production, and reduce insulation stress and losses.

Interchanged radial conductor sequences in a wave winding mat simplify stator assembly while preventing circulating currents and reducing torque ripple.

An inclined pusher lifts pre-cut hairpin conductors from the forming tool, reducing wire waste and simplifying alignment and welding.

Adjustable gripping elements and groove spacing let coil mats match receiving grooves, reducing wire stress and insulation damage during insertion.

Wider-slot assembly and alignment jigs stabilize multilayer segment coils, enabling parallel handling and faster stator slot insertion.

Adjustable press jigs form different coil segment shapes without die exchange, cutting tooling cost, downtime, and shape-change delays.

Radially widening partially assembled hairpin crowns creates space for the last insertion, then self-centers the winding for faster assembly.

OCT line scans track molten pool and weld bead geometry during laser welding, enabling real-time correction and non-destructive quality checks.

A rotating grooved tool forms coil heads and inserts coil sides into stator slots in one step, cutting assembly time and insulation damage.

Multiple inert-gas nozzles shield linearly arranged coil welds, preventing oxidation and metal vapor interference during fast galvano laser welding.

Varying magnet remanence across rotor units creates a sinusoidal field that cuts elevator motor harmonics, noise, vibration, and cost.

Pre-weld imaging and boundary-box comparison enable fast inspection of stator hairpin laser welds without sacrificing connection quality.

A grooved metal sleeve overmolded with plastic enables a high-holding-force housing joint while protecting the plastic cover across temperature changes.

Different slot pitches are handled by varying linear portion length while keeping conductor height aligned, improving winding accuracy and consistency.

A shared insulation housing and receiving structure lets stator units switch between delta and star wiring with fewer parts and simpler assembly.

A stand-off retainer lets DC motors replace individual interpole coils instead of full rewinding, cutting rebuild time and cost.

A PCM-filled heat exchanger passively absorbs and releases heat to keep electric drive fluid in range without oil pumps, reducing overheating and lubrication risk.

Radial fasteners and end-face support members secure large rotor balance weights against centrifugal force without blocking ventilation ducts.

A movable support and parallel bearing surfaces let unbent conductor bars be stacked, stored, and lifted without deformation or handling delays.

Grooved shafts clamp stator segment coils for laser welding of short stripped portions while directing heat away from insulating coating films.

A cam-guided winding core widens the radial gap during stator winding head twisting to reduce coating stress, shorting risk, and insulation handling time.

By forming the rotor body and pinion gear as one piece, this case cuts motor part count, assembly time, and overall motor length.

A multilayered wound coil stator configuration reduces potential differences between adjacent conductors to minimize insulating film thickness.