Flat-wire stator coil axial projection reduction
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Solution Overview
Problem
The existing methods for manufacturing rectangular wire stator coils result in increased axial projection of coil ends, leading to complex winding operations and higher man-hours required for assembly, especially as the number of crossed portions increases with winding pitch.
Innovation Solution
The method involves pre-forming rectangular wire elements and pieces with bent portions and using a heat conductive resin to integrate and fix them onto the stator core, reducing the axial projection and simplifying the winding process by forming sub-assemblies that can be easily assembled onto the stator core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the wire is wound around multiple teeth with extra slots, then the coil pitch increases, but the number of crossed portions increases and the axial projection length increases
Solution Approach 1:
The patent applies preliminary action by pre-forming stepped portions on the wire assembly before winding. The steps are created in advance at specific positions along the wire, allowing the coil ends to be positioned at different axial levels before the winding operation begins. This pre-positioning enables the wire to pass through slots and cross other coils without requiring excessive axial projection space during the actual winding process.
Solution Approach 2:
The patent utilizes dimensional change by introducing axial stepped positions to manage the crossing of coils. Instead of allowing all coil ends to project equally in the axial direction, the stepped portions create different axial levels (z-dimension) for different sections of the wire assembly. This dimensional differentiation allows coils to cross each other in a controlled manner while limiting the maximum axial projection length.
2Adaptability or versatility
If the coil ends are crossed to accommodate higher pitch windings, then the winding adaptability improves, but the winding operation complexity increases
Solution Approach 1:
The patent reduces winding operation complexity by performing preliminary actions of forming stepped portions and pre-arranging the wire assembly geometry before the actual winding process. The stepped portions are created in advance at calculated positions, and the wire assembly is pre-configured with these steps, so that during winding, the operator simply needs to follow the pre-determined path through slots and across coils, rather than manually managing complex crossings in real-time.
Solution Approach 2:
The patent applies segmentation by dividing the wire assembly into multiple sections with different stepped positions. Each section of the wire assembly has specifically positioned steps that correspond to different slot positions and crossing points. This segmentation allows the complex winding pattern to be broken down into manageable, pre-planned segments that can be executed systematically rather than as a single complex operation.
3Length of stationary object
If conventional weaving methods are used to suppress axial projection, then the axial length is reduced, but the manufacturing complexity increases
Solution Approach 1:
The patent eliminates the need for complex post-winding weaving operations by performing preliminary action of creating stepped portions on the wire assembly before winding. The steps are formed in advance at positions that pre-determine the axial projection of different coil ends, allowing the axial length to be controlled inherently by the geometry of the wire assembly rather than requiring additional weaving operations after winding is complete.
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 reduces the axial projection of coil ends and significantly decreases the man-hours needed for coil winding, enhancing production efficiency and heat dissipation properties while preventing electric short circuits.
Implementation Method 1
using a heat conductive resin to integrate and fix them onto the stator core
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
A rectangular wire is wound on a stator core having a plurality of teeth and a plurality of slots. A plurality of rectangular wire elements is provided by cutting a rectangular wire into a predetermined length and bending into a substantial U-shape. A plurality of rectangular wire pieces configured to form a coil by connecting predetermined end portions of the rectangular wire elements is molded as a sub-assembly. Each of the plurality of the rectangular wire elements is inserted into a predetermined pair of the slots from a first end face of the stator core such that the respective end portions of the rectangular wire elements project from a second end face of the stator core. The rectangular wire pieces of the sub-assembly are fixed to the end portions of the rectangular wire elements, thereby manufacturing a stator coil having compact coil ends easily.