Hairpin Coil Binding via Conductive Coupler

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Solution Overview

Problem

The hairpin winding method for motor stator coils faces challenges such as welding defects, high manufacturing costs, and efficiency losses due to contact resistance, primarily because it requires complex and costly welding operations, which are prone to errors and environmental pollution.

Innovation Solution

A method that eliminates welding by using conductive couplers to electrically connect hairpin coils without welding, where each pair of coils is connected through a conductor and insulated with a cap, reducing the need for expensive equipment and minimizing defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding operation is performed to connect hairpin coils, then electrical connection is achieved, but welding defects occur and reliability decreases

Engineering Contradiction:

Improvewelding defect rateVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent introduces a conductor as an intermediary component that connects the hairpin coils without direct welding. The conductor is inserted into grooves on the coil ends and secured with binding wires, serving as a mediator that eliminates the need for welding operations while maintaining electrical connectivity. This resolves the contradiction by removing the harmful welding process while preserving the electrical connection function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If welding operation is performed to connect hairpin coils, then electrical connection is achieved, but manufacturing cost increases due to expensive equipment

Engineering Contradiction:

Improveconnection reliabilityVSAvoidequipment cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive welding equipment and processes with inexpensive binding wires and simple groove structures. The binding wires are low-cost consumable items that secure the conductor to the coils without requiring expensive welding machinery. This substitution dramatically reduces equipment investment while maintaining connection reliability through the mechanical and electrical integration of the conductor-groove-wire system.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If welding operation is performed to connect hairpin coils, then electrical connection is achieved, but contact resistance increases and efficiency decreases

Engineering Contradiction:

Improvemotor efficiencyVSAvoidcontact resistance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces the welding-based electrical connection system with a mechanical insertion system. The conductor is inserted into precisely formed grooves on the coil ends, creating intimate mechanical contact that ensures low contact resistance. The binding wires provide additional mechanical pressure to maintain optimal contact between the conductor and coil surfaces, replacing the thermal welding process with a mechanical contact system that reduces contact resistance and improves motor efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Productivity

If welding operation is performed to connect hairpin coils, then electrical connection is achieved, but manufacturing time increases due to multiple operations

Engineering Contradiction:

Improvemanufacturing cycle timeVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent merges multiple separate operations into an integrated process. The conductor insertion, electrical connection, and mechanical securing functions are combined into a single operational sequence where the conductor is inserted into the grooves and immediately secured with binding wires. This eliminates the need for separate welding operations, cooling periods, and quality checks, thereby reducing manufacturing cycle time while simplifying the overall process complexity.

Inventive Principle:

Principle #5Merging (Combining)

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 simplifies the manufacturing process, reduces contact resistance, enhances motor efficiency, and improves insulation performance, thereby increasing the reliability and cost-effectiveness of motor production while avoiding the drawbacks of traditional welding methods.

Implementation Method 1

connecting the other portions of the hairpin coils through a conductor

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

fitting a cap to insulate the conductor after the conductor is connected

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS9214843B2Method of binding stator coils of motor

Publication Date: 2015.12.15 HYUNDAI MOBIS CO LTD

AI summary

A method of making an electric motor includes installing a plurality of hairpin coils in a plurality of slots, wherein the plurality of hairpin coils comprise a first hairpin coil and a second hairpin coil, the first hairpin coil comprising a first end and the second hairpin coil comprising a second end. The method further includes inserting the first and second ends into a void of an electrically conductive coupler to electrically connect the first and second ends; and placing the insulation cap over the coupler so as to protect the coupler from contacting other electric conductive materials.