Modular Stator Assembly Using Segmented Hairpin Modules
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Solution Overview
Problem
Traditional stator manufacturing in electric motors involves manual bending and interconnection of wires, which is labor-intensive and inefficient, lacking a modular approach for improved assembly and interconnection of stator coils.
Innovation Solution
A modular stator design comprising first and second stator modules with coil end regions and junctions, aligned and joined using a central fixture with thermally insulating junction apertures and tooling passageways, allowing for efficient assembly and interconnection of hair pin wires within slots defined in stator cores and crowns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual bending and interconnection of wires is used, then stator coils can be formed, but labor intensity and manufacturing time increase significantly
Solution Approach 1:
The stator is divided into multiple modular segments (first stator module and second stator module), each containing pre-assembled coil end regions and junctions. This segmentation allows parallel manufacturing of modules followed by rapid assembly, reducing overall manufacturing time and labor intensity while maintaining ease of assembly through standardized interfaces.
Solution Approach 2:
Coil end regions and junctions are pre-assembled into complete stator modules before final stator assembly. The preliminary formation of hairpin wires, coil end regions, and junctions within each module enables automated or semi-automated manufacturing processes, significantly improving productivity while the modular design maintains ease of final assembly.
2Manufacturing precision
If manual bending of wires is performed one at a time, then stator windings can be created, but manufacturing precision and consistency deteriorate
Solution Approach 1:
The stator is segmented into modular units with standardized coil end regions and junctions. Each module serves as a discrete manufacturing unit with controlled wire alignment, ensuring consistent precision. The modular structure reduces overall assembly complexity by breaking down the complex wire interconnection task into manageable, repeatable module assembly operations.
Solution Approach 2:
The invention changes the manufacturing approach from continuous manual wire bending to discrete module assembly with standardized parameters. Hairpin wires are formed with consistent geometry, coil end regions are positioned at standardized locations, and junctions are created with uniform characteristics. These parameter standardizations across modules ensure manufacturing precision while the repetitive module assembly process reduces overall complexity.
3Ease of operation
If wires are hand-inserted and hand-bent into rows, then stator connections can be established, but assembly time and labor requirements increase
Solution Approach 1:
The stator assembly is segmented into modules with pre-established wire interconnections. Each module contains complete coil end regions and junctions that are already interconnected, eliminating the need for time-consuming hand insertion and bending operations. The modular design maintains ease of operation by allowing simple module assembly while dramatically reducing total assembly time through parallel manufacturing and standardized interfaces.
Solution Approach 2:
Wire interconnections, including hairpin wire formation, coil end region creation, and junction establishment, are all performed as preliminary actions during module fabrication. This preliminary completion of complex wire work within each module eliminates the need for time-intensive manual operations during final stator assembly, reducing assembly time while the standardized module interfaces maintain ease of operation.
4Ease of manufacture
If corresponding wires are re-bent to isolate phases, then phase connections can be made, but manufacturing complexity and time increase
Solution Approach 1:
The stator is segmented into modules that can be manufactured independently with phase isolation built into the module design. This segmentation allows phase isolation to be achieved through modular architecture rather than complex wire re-bending operations, improving manufacturing efficiency while maintaining ease of phase connection through standardized module interfaces.
Solution Approach 2:
Phase isolation and wire interconnection are performed as preliminary actions during module fabrication. Hairpin wires are formed and connected within each module before module assembly, eliminating the need for time-consuming post-assembly wire re-bending operations. This preliminary completion of phase isolation and connection work improves manufacturing efficiency while the standardized module design maintains ease of manufacture.
Data Source
AI summary
A modular stator includes a first stator module and a second stator module. The first stator module includes a plurality of first coil end regions and a plurality of first junctions. The second stator module includes a plurality of second coil end regions and a plurality of second junctions. The first stator module and the second stator module are joined at the plurality of first junctions and the plurality of second junctions.