Armature Core Slot Edge Chamfering for Insulation
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Solution Overview
Problem
The existing methods for manufacturing stators with SC coils increase manufacturing costs and reduce the space factor due to the need for additional soft portions to prevent insulating member damage, while also compromising insulation properties.
Innovation Solution
A method involving the lamination of core sheets with annular yoke and tooth forming portions, where edge-removing punches chamfer the corner portions of the slots to prevent insulating member damage during conductor bending, ensuring insulation properties without additional parts or reduced space factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soft portions are added to the ends of teeth to prevent insulating member damage, then insulation properties are improved, but manufacturing cost increases
Solution Approach 1:
The harmful corner portions are removed from the core sheets before assembly, eliminating the need for additional soft portions. This extraction of the problematic feature (sharp corners) resolves the contradiction by preventing insulating member damage without adding extra components, thus maintaining insulation properties while avoiding increased manufacturing cost
Solution Approach 2:
The corner portions are removed in advance during core sheet preparation, before the insulating members are installed. This preliminary action prevents potential damage to insulating members during subsequent assembly operations, ensuring insulation properties are maintained without requiring additional protective components that would increase manufacturing cost
2Reliability
If soft portions project inward of slots to prevent insulating member contact with corner portions, then insulation properties are improved, but space factor of coils is reduced
Solution Approach 1:
Instead of adding soft portions that project inward into the slots, the harmful corner portions are extracted from the core sheets. This eliminates the need for space-consuming soft portions while still preventing insulating member damage, thus maintaining insulation properties without reducing the space factor available for coils
3Reliability
If additional parts are added to prevent insulating member damage, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The harmful corner portions are removed from the core sheets during manufacturing, eliminating the need for additional protective parts. This extraction approach improves reliability by preventing insulating member damage without requiring extra components, thereby avoiding increased manufacturing cost
Solution Approach 2:
The core sheets are designed to be self-protective by removing the harmful corner portions during their own manufacturing process. This self-service approach eliminates the need for additional protective parts from other components, improving reliability while avoiding increased manufacturing cost
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 maintains insulation properties between conductors and the armature core while preventing insulating member damage and maintaining the space factor, thus controlling manufacturing costs and performance.
Implementation Method 1
a pressing step for removing the edge of a corner portion of an axial opening edge of the slot in the core sheets that is located at least at an axial end of the armature core
Data Source
AI summary
A method for manufacturing a stator configured to ensure insulation properties between a conductor and an armature core while preventing a manufacturing cost from increasing and preventing a space factor from lowering. In an edge-removing step, a plurality of independent edge-removing punches, which correspond to one slot S or two or more slots S, press and chamfer a corner portion of an axial opening edge of the slot in an axial end core sheet of the armature core.