Hairpin Winding Motor Stator Assembly Fixing Cap
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Solution Overview
Problem
Conventional hairpin coil winding motors face challenges with ends being burned during welding and require costly destructive inspections for quality management, affecting productivity and increasing inspection costs.
Innovation Solution
A stator assembly design for hairpin winding motors that eliminates the need for welding between hairpin coil ends by using a fixing cap and member to secure exposed ends, preventing separation and electrical contact, thus reducing assembly time and inspection costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect hairpin coil ends, then electrical connection is achieved, but ends are burned and welding quality requires costly destructive inspection
Solution Approach 1:
The patent extracts and eliminates the welding process from the hairpin coil assembly. Instead of welding coil ends together, the invention uses a fixing cap with fixing members to mechanically secure the coil ends in their respective slots, completely removing the harmful welding operation that causes end burning and requiring destructive inspection.
Solution Approach 2:
The fixing cap acts as an intermediary component between the hairpin coil ends and the motor assembly. This mediator provides a non-destructive method to secure the coil ends, replacing the direct welding process with a mechanical fixing system that avoids thermal damage and eliminates the need for destructive quality inspection.
2Reliability
If welding process is used for connecting hairpin coil ends, then electrical connection is achieved, but inspection costs increase due to required destructive testing
Solution Approach 1:
The patent removes the welding process entirely from the manufacturing flow. By replacing welding with mechanical fixing using fixing caps, the invention eliminates the need for costly and time-consuming destructive inspections such as tensile strength tests, enabling continuous quality assurance without production interruption.
3Ease of manufacture
If hairpin coil ends are twisted for physical contact, then connection is achieved, but separation may occur and reliable electrical connection is not ensured
Solution Approach 1:
The fixing cap serves as a mediator that provides both mechanical retention and electrical insulation. It secures the twisted coil ends in position while preventing separation, and simultaneously provides insulation to ensure reliable electrical connection without the risk of short circuits or connection failures.
Solution Approach 2:
The fixing cap appears to combine insulating and structural properties, creating a composite solution that simultaneously achieves mechanical fixation and electrical insulation. This composite approach ensures both ease of assembly and reliable electrical connection without the drawbacks of simple twisting alone.
Data Source
AI summary
The present disclosure relates to a stator assembly of a hairpin winding motor. The stator assembly includes a stator core and hairpin coils. The hairpin coils include a first end including a pair of respective ends of first two hairpin coils arranged adjacent to each other in a radial direction, a second end including a pair of respective ends of second two hairpin coils arranged adjacent to each other outside the first end in the radial direction, and a third end including a pair of respective ends of third two hairpin coils arranged adjacent to each other outside the second end in the radial direction. Here, such first to third ends are repetitively arranged in plural along a circumferential direction, and a fixing cap fixes a preset number of ends among the plurality of first to third ends repetitively formed along the circumferential direction.