Coil Module Design for Automated Stator Electrical Contacting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing stators for electric motors are complex and lack automation, particularly in the electrical contacting of coils, which hinders efficient and cost-effective manufacturing.
Innovation Solution
A coil module design featuring a coil holder with first and second webs for easy coil winding and electrical contact, allowing for automated production and integration with a stator's return body using retaining pins and a contact circuit board, enabling simple and automated electrical connection via welding or soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional methods are used for producing stators, then manufacturing can be done with existing processes, but the production process is complex and lacks automation
Solution Approach 1:
The stator production process is divided into separate modular components: coil modules with pre-attached contact points, return body segments, and circuit board assemblies. This segmentation allows each component to be manufactured and prepared independently, then assembled automatically, reducing overall process complexity while enabling automation.
Solution Approach 2:
Contact points are pre-attached to coil modules before final assembly, and coils are pre-wound on coil holders. These preliminary actions prepare components in advance with standardized interfaces, enabling automated assembly systems to simply position and join pre-prepared modules rather than performing complex operations during final assembly.
2Productivity
If manual electrical contacting of coils is used, then flexibility in manufacturing is maintained, but manufacturing efficiency and cost-effectiveness decrease
Solution Approach 1:
The coil modules are designed with self-aligning features where contact points are automatically positioned relative to the coil windings. The module structure itself facilitates the electrical contacting process, allowing automated systems to simply press or join components together without requiring complex manual wiring operations.
Solution Approach 2:
The coil holder acts as an intermediary component that simplifies the electrical contacting process. It provides standardized contact surfaces and positioning features that mediate between the coil windings and the external circuit board, enabling automated joining operations rather than direct complex wiring.
3Loss of time
If complex assembly processes are used for integrating coils with return body, then all components can be integrated, but the assembly process becomes time-consuming and labor-intensive
Solution Approach 1:
Multiple functions are merged into the coil module assembly: the coil windings, contact points, coil holder, and positioning features are combined into a single integrated module. This merging eliminates the need for separate operations to attach each component individually, allowing automated systems to handle one integrated unit and significantly reducing assembly time and complexity.
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
Facilitates the production of stators with high automation, reducing manufacturing complexity and cost by allowing for efficient electrical contacting of coils, enabling a more streamlined and efficient assembly process.
Implementation Method 1
a coil (86) arranged on the coil holder (114)... The coil can be produced in a simple manner on the coil holder, in particular by winding
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A coil module for a stator of an electric motor is provided, comprising a coil holder, a coil which is arranged on the coil holder, a first web and a second web, wherein between the first and the second web a first coil section and a second coil section for making contact with a motor circuit are situated.