Brushless Motor Stator Single Wire Winding Process
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Solution Overview
Problem
The manufacturing of brushless motor stators is labor-intensive and error-prone due to the need for welding multiple end points of electromagnetic wires on a wiring board, which is time-consuming and prone to errors.
Innovation Solution
A brushless motor stator design that uses a single electromagnetic wire to form three extended segments around the stator core, coil carrier, and pole shoes, eliminating the need for multiple spot-welding by utilizing a common welding piece and reducing the requirement for a separate wiring board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple stator windings are wound around six pole shoes using multiple electromagnetic wires, then each winding can be independently formed, but the number of welding operations increases significantly making the process labor-intensive and time-consuming
Solution Approach 1:
The patent combines multiple separate winding operations into a single continuous winding process. One electromagnetic wire is wound around the tooth base and multiple teeth to form all three stator windings (U-phase, V-phase, W-phase) simultaneously, eliminating the need for multiple separate wires and multiple welding operations. This merging of operations directly resolves the contradiction by maintaining winding independence while dramatically improving manufacturing efficiency.
Solution Approach 2:
The single electromagnetic wire performs multiple functions: it forms all three stator windings (U, V, W phases) and provides all six output terminals through its extended segments. This multi-functional approach eliminates the need for separate wires for each winding, reducing the number of welding operations from potentially 12+ welds to just 3 welds on the wiring board, thus resolving the efficiency problem while maintaining manufacturing simplicity.
2Manufacturing precision
If multiple electromagnetic wires are used for multiple stator windings, then each winding can be formed around its pole shoe, but the number of welding operations increases making the process error-prone
Solution Approach 1:
By merging multiple winding formations into one continuous winding process using a single electromagnetic wire, the patent reduces the number of discrete welding operations from multiple (one per wire end) to just three (one per phase output). This reduction in welding operations directly lowers the error rate and improves reliability while maintaining precise winding formation around each pole shoe through the continuous winding process.
3Ease of operation
If two end points of each electromagnetic wire are welded on the wiring board, then power can be supplied to each stator winding, but the welding process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent merges multiple power supply connections into a unified structure where a single electromagnetic wire provides all three phase outputs (U, V, W) with only three welding points on the wiring board instead of six or more. This consolidation maintains ease of power supply connection while reducing total welding time and labor requirements by approximately 50% or more.
Solution Approach 2:
The single electromagnetic wire serves as a universal conductor that provides power supply connections for all three stator windings simultaneously. Its extended segments beyond the stator frame serve as all six output terminals (two per phase), eliminating the need for multiple separate wires and reducing welding operations to just three points on the wiring board, thus resolving the time-consuming welding problem while maintaining ease of power supply.
4Ease of manufacture
If multiple stator windings are formed with separate electromagnetic wires, then each winding can be independently wound, but the overall device complexity increases
Solution Approach 1:
The patent merges multiple separate electromagnetic wires into a single continuous wire that forms all three stator windings. This reduces the number of components from multiple wires to one wire, simplifying the device structure and reducing assembly complexity while maintaining the ability to independently form each winding through the continuous winding process around different pole shoes.
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 design simplifies the manufacturing process by reducing the number of spot-welding points, eliminates the need for additional wiring, and allows for direct electrical connection to motor terminals, thereby enhancing efficiency and reducing production costs.
Implementation Method 1
an electromagnetic wire to wind around the tooth base, the multiple teeth and the multiple pole shoes
Data Source
AI summary
A brushless motor stator includes a stator core and a stator winding. The stator core has a stator frame, a coil carrier and multiple pole shoes. The coil carrier is mounted on one of the two openings of the stator frame and has a tooth base and multiple teeth. The teeth are formed on a top surface of the tooth base. The pole shoes are formed on the inner annular surface of the stator frame. The stator winding is formed by using a single wire to wind around the tooth base, the multiple teeth and the multiple pole shoes, and passing through three of the multiple slots of the coil carrier to extend beyond the outer annular surface of the stator frame to form three extended segments to correspond to U-phase, V-phase and W-phase output terminals of a motor, thereby reducing the number of spot-welding on a wiring board.