Linear Stator Coil Winding for Three-Phase Y Connection
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Solution Overview
Problem
Conventional stator coil winding machines face difficulties in efficiently winding coils on stator cores for BLDC motors, leading to inefficient use of space and suboptimal coil characteristics due to challenges in manufacturing and winding techniques.
Innovation Solution
A stator coil winding machine with a stator transfer unit, winding guide unit, tension adjusting unit, and controller that enables precise coil winding on linear-type stator cores using a three-phase Y connection, allowing for sequential and directional winding to transform the stator into a ring type, facilitating efficient coil placement and adaptation to various stator types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional winding methods are used on ring type stator cores, then the manufacturing process becomes complex and difficult, but the patent aims to simplify the winding process while maintaining effective coil placement
Solution Approach 1:
The stator core is divided into multiple segments that can be separately positioned and wound. Each segment can be independently handled by the winding mechanism, allowing the complex ring type stator to be manufactured through repeated simple winding operations on individual segments rather than requiring a single complex winding process on the entire ring structure.
Solution Approach 2:
The patent transforms the winding approach by considering the stator segments in a linear arrangement rather than attempting to wind the complete ring structure at once. The winding mechanism operates on segments positioned in a line, effectively changing the dimensional approach from a circular ring-wide operation to a linear segment-by-segment process, simplifying the overall manufacturing complexity.
2Volume of moving object
If conventional winding approaches are used, then space utilization in the BLDC motor is insufficient, but implementing efficient winding requires complex manufacturing processes
Solution Approach 1:
The stator segments are pre-positioned in a linear arrangement before the winding process begins. This preliminary positioning allows the winding mechanism to efficiently place coils in optimal positions for maximum space utilization, rather than attempting to achieve proper coil placement during a complex single-step winding process on the complete ring structure.
3Quantity of substance
If coils are wound on ring type stator cores using conventional methods, then the amount of coil wound is insufficient, but increasing coil amount requires more complex winding techniques
Solution Approach 1:
The winding process operates continuously on multiple stator segments arranged in a line, with the winding mechanism repeatedly performing the same coil-winding action on each segment. This continuous repeated action allows sufficient coil quantity to be wound across all segments without requiring increasingly complex winding techniques for each additional coil.
Data Source
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AI summary
The present invention relates to a stator coil winding machine including: a stator transfer unit adapted to transfer a linear type stator having a plurality of stator cores in directions of X and Y axes; a winding guide unit adapted to guide the transferred stator to coil winding; a winding unit adapted to wind a coil on the stator; a tension adjusting unit adapted to adjust tension on the coil being wound on the stator; and a controller adapted to control operations of the stator transfer unit, the winding guide unit, and the winding unit to allow the coil to be wound on the stator by means of three-phase Y connection on the basis of a previously set winding sequence.