Alternator Stator Winding Insertion with Crenellated Segments
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Solution Overview
Problem
Existing methods for inserting phase windings into stator slots of rotating electrical machines, such as motor vehicle alternators, result in tightly packed winding overhangs that hinder air circulation, non-symmetrical overhangs, high insertion forces, and poor transmission of forces between phases, affecting the quality and efficiency of the product.
Innovation Solution
A method involving shaping the conductive wire into crenellations and linking segments, using a cylindrical insertion tool where turns are wound alternately around the tool and inserted in reverse order, allowing for controlled placement and increased slot filling rate, with optional local shaping of the wire to optimize slot occupancy and air passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If phase windings are inserted sequentially using a receiving wheel, then the insertion process is simple, but the winding overhangs become tightly packed and non-symmetrical, hindering air circulation
Solution Approach 1:
The patent merges the insertion of multiple phase windings into a single simultaneous operation using a cylindrical tool with multiple insertion points. All phases are inserted at the same time rather than sequentially, which prevents the tightly packed and non-symmetrical overhangs that occur with sequential insertion. This merging approach maintains manufacturing simplicity while eliminating air circulation resistance.
2Quantity of substance
If the rate of filling the slots is increased, then more copper can be accommodated, but the insertion forces become very large and may prejudice product quality
Solution Approach 1:
The patent segments the winding structure into crenellations with multiple lateral branches that can be inserted into different slots simultaneously. The cylindrical insertion tool has multiple insertion points arranged circumferentially, allowing the winding to be divided into segments that are inserted in parallel. This segmentation enables high copper density while distributing insertion forces across multiple points, preventing excessive force concentration that would damage product quality.
3Productivity
If all phases are inserted simultaneously, then productivity increases, but the device complexity increases
Solution Approach 1:
The cylindrical insertion tool is designed with multi-functionality, serving as both the structural support for multiple phase windings and the insertion mechanism itself. The tool features circumferential insertion points that can accommodate multiple phases simultaneously, and the same tool structure is used for both holding the windings during shaping and for the actual insertion operation. This universal design achieves high productivity without proportionally increasing device complexity.
Data Source
AI summary
A method of inserting an undulating winding into an alternator stator. The method comprises the following steps consisting of shaping each phase winding into a succession of crenels comprising two lateral branches which are intended to be attached at a position for reception in a slot, positioning the windings on an insertion tool and inserting the turns into the slots of the stator in the reverse order to the winding order. The windings are wound around the insertion tool simultaneously, and the turns that succeed one another in a determined winding order belong alternatively to different windings.