DC Motor Stator Winding with Deflection Means
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Solution Overview
Problem
Conventional DC motor stator winding processes face challenges in achieving process-reliable production, simple assembly, and high efficiency due to the limitations of the manufacturing process, which restricts the realization of desirable geometries and increases the risk of short circuits.
Innovation Solution
The method involves using a stator core with an insulating body and a needle winding machine, guiding the winding wire radially inward and outward between projections, and using contact units with hook-like projections for secure electrical connections, while ensuring sufficient spacing to prevent short circuits and optimize wire laying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a needle winding machine is used with a hollow winding needle, then the winding process can be automated, but the minimum diameter of the winding needle and required spacing limit the achievable geometries
Solution Approach 1:
A deflection means is introduced as an intermediary element to guide the winding wire around the pole. This mediator allows the wire to be routed in complex three-dimensional paths that would be impossible with a simple hollow needle, enabling versatile geometries while maintaining automated winding processes.
Solution Approach 2:
The winding wire is guided not only radially but also axially and tangentially through the use of deflection means positioned at multiple levels. This multi-dimensional routing approach overcomes the limitations of conventional two-dimensional needle winding, allowing complex spatial geometries to be achieved.
2Reliability
If the winding wire is guided radially inwards and outwards with sufficient spacing, then short circuit risks are reduced, but the installation space required increases
Solution Approach 1:
The deflection means utilizes the axial dimension to route the winding wire, allowing sufficient radial spacing for reliability while containing the overall structure within compact dimensions. The wire is guided axially between poles and then radially to contact units, optimizing space utilization.
Solution Approach 2:
The deflection means is pre-positioned on the stator before winding begins. This preliminary arrangement of the guiding structure ensures that the winding wire follows the correct path with adequate spacing from the start, preventing short circuits while minimizing the space required for wire routing.
3Ease of manufacture
If contact units are located far in front axially or arranged radially, then wire routing is simplified, but assembly complexity increases
Solution Approach 1:
The contact units are merged with the pole structure, being arranged radially on the poles rather than being separate axial components. This integration simplifies the overall assembly by reducing the number of separate parts and their associated mounting operations, while the deflection means handles the wire routing 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
This approach enables reliable and efficient winding of the DC motor stator, reducing the risk of short circuits and allowing for more complex geometries, thereby improving assembly and efficiency.
Implementation Method 1
guiding the winding wire (10) from the stop point between two projections (9) of the insulating body (7) radially inwards; winding a coil around a pole (4); guiding the winding wire (10) radially outwards between two projections
Implementation Method 2
leading the winding wire (10) around a tool-fixed deflection means radially outside of the return ring
Implementation Method 3
radial inward deformation of the winding wire sections running radially outwards, up to an area within the yoke ring
Implementation Method 4
Welding the contact sections to the winding wire sections
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a DC motor (1) with a permanent magnet inner rotor (2) rotatably mounted about a longitudinal motor axis (19) and a wound stator core (3) with pronounced inwardly directed poles (4) which are integrally formed with a backplate ring (5) in the circumferential direction and separated from each other by stator slots (6), an insulating body (7) which lines the stator slots (6) and has a backplate ring cover (8) formed with axially parallel projections (9) which covers an axial end face of the backplate ring (5), wherein a winding wire (10) is wound around each pole (4) and guided radially outwards around two projections (9) to the spatially adjacent pole, each pole being assigned a projection (9). The invention further relates to a method for such a DC motor.The object of the invention is to ensure reliable manufacturing, simple assembly, and good efficiency in a DC motor of the generic type. This object is achieved according to the invention by the features of claim 1 and method claim 13.