Integrated Flat-Wire Stator Winding Without Coil Welding
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Solution Overview
Problem
Existing stator windings in electric vehicle motors face high production costs, labor intensity, and quality issues due to the need for welding multiple coils, which are time-consuming and prone to poor connections.
Innovation Solution
A stator winding formed by winding a flat wire to create multiple coils that share a single flat wire, eliminating the need for separate coil connections, such as welding, and ensuring consistent winding direction and structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate coils are welded together to form a stator winding, then the stator winding can be assembled, but the welding cost increases, production efficiency decreases, and connection reliability is poor
Solution Approach 1:
The patent merges multiple separate coils into a single integrated stator winding structure. Instead of assembling and welding multiple discrete coils together, the invention creates one continuous winding that forms all necessary coil structures, eliminating the need for joining operations and improving both reliability and production efficiency.
Solution Approach 2:
The patent segments a single continuous stator winding into multiple functional coil sections that are distributed around the stator. This segmentation is achieved through the winding process itself rather than through assembly, allowing the single winding to serve multiple functional purposes while maintaining structural integrity.
2Ease of manufacture
If multiple separate coils are welded together to form a stator winding, then the stator winding can be assembled, but the labor intensity increases and production cost increases
Solution Approach 1:
The patent combines multiple coil-forming operations into a single continuous winding process. By using one continuous wire to create all coil sections in sequence, the manufacturing process becomes simpler and more automated, reducing both labor intensity and production costs while maintaining ease of manufacture.
Solution Approach 2:
The single continuous winding structure is self-forming and self-positioning. As the wire is wound through the stator slots, it automatically creates the correct coil geometries and positions without requiring manual assembly or alignment operations, thereby improving ease of manufacture and production efficiency.
3Manufacturing precision
If separate coils are connected by welding, then the stator winding can be formed, but the connection process is complicated and welding quality cannot be guaranteed
Solution Approach 1:
The patent eliminates the welding connection process entirely by merging all coil sections into a single continuous winding. This removes the source of welding quality issues and process complexity, as there are no joints or connections requiring welding operations.
Solution Approach 2:
The patent extracts and removes the welding operation from the manufacturing process. By designing a single continuous winding structure, the invention eliminates the need for joining processes, thereby removing the complexity and quality control issues associated with welding.
4Object-affected harmful factors
If separate coils are welded together, then the stator winding can be assembled, but fireproof asbestos must be laid first which is cumbersome and harmful to health
Solution Approach 1:
The patent removes the welding operation from the manufacturing process by using a single continuous winding structure. This extraction of the welding step eliminates the need for fireproof asbestos barriers, thereby removing the health hazard while maintaining ease of manufacture through the simplified winding process.
Solution Approach 2:
By combining all coil sections into one continuous winding, the patent eliminates the welding step that would require fireproof measures. This merging approach removes the harmful aspect entirely while keeping the manufacturing process simple and straightforward.
Data Source
AI summary
The utility model relates to the technical field of motor structures, and particularly relates to a stator winding, a stator and a motor. The stator winding is formed by winding a flat wire, a part of the flat wire is wound to form at least two coils arranged at intervals, and the coils are consistent in winding direction and located on the same side of the flat wire. By using the solution, the technical effects of integrally forming the stator winding and sharing a flat wire by the coils located on the stator winding are achieved. Compared with the technical solution in the prior art that single coils are connected to form a stator winding, the technical solution in the utility model of integral forming has the following advantages: firstly, the connection difficulty in the prior art is avoided, and the production efficiency of the stator winding is greatly improved; secondly, unnecessary connecting points on the stator winding are avoided, and the quality of the stator winding is improved; and thirdly, the production process of the stator winding is reduced, and the production cost and the labor intensity are lowered.