Angled Stamping of Stator Coil Sides for Uniform Slot Filling
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Solution Overview
Problem
Conventional stator production methods, such as the pull-in method, limit electrical filling factors to 40-50%, and stamping processes face issues with non-uniform wire deformation and overheating due to uneven pressure distribution, leading to suboptimal slot filling and copper displacement into inactive regions.
Innovation Solution
The method involves stamping coil sides at an angle greater than zero relative to the slot row, using two separate stamping chambers to achieve uniform mechanical filling and prevent over-deformation, allowing for electrical filling factors greater than 60% by ensuring uniform deformation and avoiding copper displacement into inactive regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wires are stamped in the radial direction (direction of slot height), then the stamping pressure concentrates on the wire in contact with the stamping punch, but this leads to non-uniform deformation and over-deformation of individual wires
Solution Approach 1:
The patent changes the stamping direction from the radial direction (slot height direction) to an oblique direction at an angle of 10° to 45° relative to the slot row. This dimensional change in the stamping force vector distributes the pressure more uniformly across all wires in the slot row, preventing concentration of stress on individual wires and achieving uniform deformation without local pinching or overheating.
2Quantity of substance
If the stamping pressure is increased to achieve greater than 100% slot filling on the punch, then more copper is pushed into the slot, but copper is displaced into the winding heads and electromagnetically inactive region
Solution Approach 1:
By changing the stamping direction to an oblique angle of 10° to 45° relative to the slot row, the patent achieves more efficient copper compaction in the radial direction. This angular stamping direction prevents copper from being pushed forward into the winding heads and electromagnetically inactive regions, while still achieving the desired slot filling level of greater than 60% with proper copper positioning.
3Ease of manufacture
If conventional pull-in method is used for stator production, then the production process is simple, but the electrical filling factor is limited to 40-50%
Solution Approach 1:
The patent applies stamping pressure to the coil sides at an oblique angle of 10° to 45° relative to the slot row, rather than in the conventional radial direction. This parameter change in the stamping force direction, combined with controlling the stamping depth to 0.5mm to 2mm, enables achieving an electrical filling factor of greater than 60% while maintaining manufacturing feasibility.
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 optimized electromagnetic designs with electrical filling factors greater than 60% by ensuring uniform mechanical filling and preventing copper displacement, thus improving power generation efficiency with reduced material usage and minimizing overheating risks.
Implementation Method 1
shaping is performed by means of a force F, the direction of this force being at an angle α of greater than zero in relation to the slot row 90
Data Source
AI summary
Method for stamping multiple coil sides (96) for a stator winding (18), characterized in that the multiple coil sides (96) are arranged in a grooved row (90), the shaping process taking place at a force (F), the direction of which runs at an angle (α) greater than zero relative to the grooved row (90).