Additive Base Winding Assembly for Compact Stator Manufacturing
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Solution Overview
Problem
The manufacturing of stators for electrical machines is time-consuming and costly due to the need for precise windings and complex geometric specifications, with existing methods requiring significant installation space for winding heads and being prone to errors.
Innovation Solution
A method for manufacturing a base winding assembly using an additive manufacturing process, where conductor loops open on one side are arranged such that closed ends form one face and open ends form the opposite face, allowing for efficient assembly with a stator core and reducing installation space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional winding methods are used to manufacture stator windings, then the windings can be produced with adequate mechanical strength, but the manufacturing time and cost increase significantly due to the complexity of precise windings and geometric specifications
Solution Approach 1:
The patent replaces traditional mechanical winding processes with an additive manufacturing process. The base winding assembly is manufactured by layer-by-layer application and local consolidation of build-up material, eliminating the need for complex mechanical winding operations while achieving high precision windings and reducing manufacturing time
2Quantity of substance
If high fill factors are achieved by winding from insulated conductors, then the electrical efficiency improves, but the installation space required for winding heads increases due to the need to accommodate many individual conductors and their bending radii
Solution Approach 1:
The patent merges multiple individual conductors into a single integrated base winding assembly manufactured by additive manufacturing. This consolidation eliminates the need for separate winding heads for each conductor, significantly reducing the installation space required while maintaining high fill factors through the layer-by-layer manufacturing process
3Manufacturing precision
If multiple additive manufacturing devices are used to manufacture the entire stator with different materials, then the manufacturing precision and material properties improve, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent segments the stator manufacturing into two distinct components: a base winding assembly manufactured by additive manufacturing and a stator core manufactured separately. This segmentation allows each component to be optimized independently, reducing the need for multiple additive manufacturing devices while maintaining high manufacturing precision for both parts
4Ease of manufacture
If winding sections are mechanically connected using contacting elements, then the stator can be assembled from separate components, but the assembly process becomes time-consuming and error-prone
Solution Approach 1:
The patent incorporates connection elements directly into the base winding assembly during the additive manufacturing process, before final assembly with the stator core. This preliminary integration ensures reliable connections are built-in from the start, eliminating the need for separate mechanical connection steps and reducing assembly errors
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
This approach enables the precise and efficient manufacture of stators with reduced installation space requirements, minimizing errors and costs while maintaining high manufacturing accuracy.
Implementation Method 1
the base winding assembly is manufactured by an additive manufacturing process in which a layer-by-layer application and local consolidation of build-up material takes place
Data Source
AI summary
A method of manufacturing a base winding assembly of a stator. The base winding assembly includes a plurality of conductor loop groups each formed of a plurality of conductor loops that are open on one side, wherein the closed ends of the conductor loops that are open on one side can be arranged at one face of the base assembly and the open ends can be arranged at the opposite face side of the base assembly, wherein the manufacturing of the base winding assembly is done by an additive manufacturing process in which a layer-by-layer application and local solidification of build-up material takes place. Furthermore, a method for manufacturing a stator for an electric machine, as well as a base winding group of a stator and a stator are proposed.