Continuous Stator Winding Method for Electric Machine Production
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Solution Overview
Problem
Current methods for winding stators in electric machines, such as the pull-in and needle winding techniques, require additional manual steps for phase insulation, interconnection, and shaping, which increase complexity and reduce efficiency.
Innovation Solution
A method where coil groups of each phase are continuously wound with a single winding wire without interruption, allowing for seamless wire transitions between coil groups, followed by a separation step to form coil ends, which are then electrically connected, simplifying the production process and reducing manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pull-in technology is used to wind stators, then loose copper coils can be drawn into longitudinal slots, but additional manual process steps are required for phase insulation, interconnection, shaping, and bandaging
Solution Approach 1:
The patent combines multiple separate winding operations into a single continuous winding process. The winding wire is fed continuously through all coil groups without interruption, merging what were previously separate winding steps into one integrated operation, thereby reducing the number of manual process steps required
Solution Approach 2:
The patent performs preliminary actions by pre-configuring the winding wire with connection elements and insulation layers before the winding process begins. This allows phase insulation and interconnection to be integrated into the winding process itself rather than requiring separate manual steps after winding
2Manufacturing precision
If needle winding technique is used to place winding wires directly at defined points, then precision is improved, but manual connection steps are still required after winding
Solution Approach 1:
The patent merges the winding process and wiring process into a single continuous operation. By feeding the winding wire continuously through all coil groups and forming connections during the winding process itself, the separate wiring step that traditionally followed needle winding is eliminated
Solution Approach 2:
The patent maintains continuous useful action by feeding the winding wire without interruption through all coil groups and completing both winding and connection operations in one continuous process, eliminating idle time and separate manual intervention steps
3Reliability
If coil ends are connected manually after winding according to predetermined wiring diagrams, then electrical connections are established, but productivity is reduced due to manual handling
Solution Approach 1:
The winding wire serves itself by being continuously fed and automatically forming electrical connections between coil groups during the winding process. The connection elements are attached to the wire in advance, allowing the wire to create its own electrical connections without external manual intervention
Solution Approach 2:
Connection elements and insulation layers are preliminarily applied to the winding wire before the winding process begins. This preliminary preparation allows electrical connections to be formed automatically during winding, eliminating the need for manual connection steps after winding
Data Source
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AI summary
The invention relates to a method for winding a winding carrier (2), in particular a stator of an electric machine (1), using needle winding technology, in which the winding carrier (2) has alternating teeth and slots (4) in a circumferential direction and, in the wound state, has at least two coil groups (5.1 to 5.4) per phase (u, v, w) offset from each other in the circumferential direction, each coil group having at least one coil (6, 7) with coil turns, in which method a winding wire (15) emerges from a winding needle (13) under wire tension and is laid in the winding carrier (2) according to a predetermined winding scheme (Figs. 2 to 7), forming the coils (6, 7) whose coil ends (21) are electrically connected to each other in a connecting process according to a predetermined connecting scheme. According to the invention, the winding scheme is designed such that the coil groups (5.1 to 5.4) are connected to each other in a connecting process according to a predetermined connecting scheme.4) Each phase (u, v, w) is continuously wound in the circumferential direction with the winding wire (15) without any wire interruption. In a separation step at the end of the winding process, the wire bundle is separated at the respective wire transition (16) between a coil output (A) of one coil group and a coil input (E) of an adjacent coil group, forming the coil ends (21).