Axial Air-Gap Motor Stator Assembly for Continuous Coil Winding
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Solution Overview
Problem
The existing methods for assembling axial air-gap electronic motors require significant labor and time due to the separate handling and wire connecting of core members, which complicates the stator construction and coil winding process.
Innovation Solution
The implementation of connecting means such as rib pairs, locking claws, and engagement portions on the flange portions of core members allows for easy connection and positioning, enabling continuous coil winding without cutting, and reduces the need for manual wire connecting by forming a ring structure with the core members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If core members are assembled separately and connected manually, then the stator construction is flexible, but the assembling time and labor increase significantly
Solution Approach 1:
The connecting means (protrusions and recesses) are pre-formed on the core members during manufacturing. This preliminary preparation allows the core members to be quickly connected during assembly without requiring manual fabrication or adjustment of connecting features, thus resolving the contradiction between construction flexibility and assembly speed
Solution Approach 2:
The connecting means integrates the connection function directly into the core member structure through protrusions and recesses. This merging of connection features with the core members themselves eliminates the need for separate connection components and manual assembly operations, improving productivity while maintaining construction flexibility
2Productivity
If core members are connected with connecting means, then the coil winding time is reduced, but the device complexity increases
Solution Approach 1:
The stator is segmented into multiple core members, each with its own connecting means. This segmentation allows the coil winding process to proceed sequentially from one core member to the next without requiring complete disassembly or complex reconfiguration, thus reducing overall coil winding time while managing device complexity through modular design
Solution Approach 2:
The connecting means (protrusions and recesses) serves multiple functions: it provides mechanical connection between core members, ensures proper alignment during assembly, and facilitates sequential coil winding. This multi-functionality reduces the need for additional components, thereby limiting the increase in device complexity while achieving faster coil winding
3Ease of operation
If core members are handled separately, then the assembly process is simple, but the wire connecting work requires much labor
Solution Approach 1:
The connecting means merges the mechanical connection function with the electrical connection pathway. The protrusions and recesses create both structural alignment and continuous pathways for coil winding across core members, eliminating the need for separate wire connecting operations and reducing wire connecting time while maintaining assembly simplicity
Solution Approach 2:
The connecting means is pre-configured on each core member to establish both mechanical and electrical continuity. This preliminary preparation of connection pathways eliminates the need for manual wire connecting during assembly, reducing wire connecting time while keeping the assembly process simple and straightforward
Data Source
AI summary
In a method for manufacturing an axial air-gap electronic motor, a plurality of core member and a plurality of dummy members are prepared, wherein each of the dummy members has a shape same as that of the core members. Then, the plurality of core members is arranged such that teeth surfaces of the core members face each other, and the dummy member is arranged between predetermined core members. Thereafter, a coil is wound from one end side toward the other end side of the core members through the dummy member continuously without cutting. A part of the coil corresponding to a transition wire set between the core members is wound on the dummy member.