Modular Stator Winding Assembly for Electric Aircraft Motors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current stator manufacturing methods for electric aircraft motors face challenges in efficiently creating modular winding sets and installing teeth segments, which can lead to inefficiencies and potential turn-to-turn failures in the motor.
Innovation Solution
A manufacturing apparatus and method that includes a work-holding device, a winding device to create modular winding sets by winding a continuous conductor on each tooth, and an installation device to securely integrate the segments into the stator, utilizing a computing device for automated control and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If individual teeth are wound then soldered or joined to create multiple phase segments, then the stator can be manufactured with modular segments, but the manufacturing process becomes complex and prone to turn-to-turn failures
Solution Approach 1:
The stator is divided into multiple modular segments, each containing a complete set of windings for one or more phases. Each segment is independently manufactured and then assembled into the complete stator, enabling modular construction while maintaining winding integrity within each segment.
Solution Approach 2:
A segment support structure serves as an intermediary component that holds the coil forms and windings during the winding process. This support structure provides a stable platform for creating modular segments without requiring complex joining operations between individual teeth.
2Productivity
If traditional winding and joining methods are used for individual teeth, then manufacturing can be performed with simple equipment, but productivity is reduced and manufacturing precision is compromised
Solution Approach 1:
The coil forms are prepared and positioned on the segment support structure before the winding operation begins. This preliminary arrangement of components streamlines the winding process and enables more efficient manufacturing of modular segments.
Solution Approach 2:
The segment support structure is designed to be movable, allowing it to be positioned and adjusted during the winding process. This dynamic capability enables flexible manufacturing while maintaining precision and efficiency.
Data Source
AI summary
An apparatus for manufacturing a stator for an electric aircraft motor, wherein the apparatus includes at least a manufacturing device. The manufacturing device further includes at least a work-holding device configured to hold a first segment of teeth. The manufacturing device further includes at least a winding device configured to create a modular winding set in the first segment of teeth, wherein creating a modular winding set further include acquiring a continuous conductor and winding a continuous conducting coil upon each tooth of the plurality of teeth using the continuous conductor. The manufacturing device further includes at least an installation device configured to install a plurality of segment of teeth into the stator.