Electric Motor End Cap Grooves Guide Winding
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Solution Overview
Problem
The existing methods for producing electric motors with laminated cores are complex and lack reproducibility in winding, leading to inefficiencies and quality control issues during the manufacturing process.
Innovation Solution
The electric motor design incorporates an end cap with specific shaping features that guide and protect the laminated core, ensuring precise winding and cohesion, while a plastic retaining ring aids in segment alignment and lubrication, allowing for faster and more reproducible production with reduced path deviations and increased winding speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional winding methods are used without guidance features, then the winding process is simpler, but the reproducibility and precision of winding are poor
Solution Approach 1:
The end cap serves as an intermediary component between the winding tool and the stator core. It introduces guiding features (grooves, domes, recesses) that mediate the winding process, ensuring consistent wire path and position without requiring complex adjustments to the winding tool itself.
Solution Approach 2:
The end cap is prepared in advance with pre-formed guiding features (grooves, domes, recesses) that define the winding path before the winding process begins. This preliminary structuring ensures that subsequent winding operations are automatically guided with high precision.
2Productivity
If winding speed is increased to improve productivity, then production efficiency increases, but path deviations in winding increase
Solution Approach 1:
The end cap provides a rigid, pre-structured guiding framework that cushions against path deviations caused by high-speed winding variations. The grooves and domes act as physical constraints that maintain winding accuracy even when tool path variations occur at higher speeds.
3Ease of manufacture
If the laminated core is not protected during assembly, then the assembly process is simpler, but the edges of the core are damaged
Solution Approach 1:
The plastic retaining ring is designed with protective features that cushion and protect the laminated core edges during the assembly process. The softer plastic material absorbs mechanical stresses and prevents damage to the delicate core edges while facilitating insertion into the motor housing.
4Productivity
If individual segments are not aligned precisely, then assembly is faster, but the circular arrangement and structural integrity are compromised
Solution Approach 1:
The retaining ring acts as an intermediary component that mediates the alignment of individual stator segments. It provides mechanical features (protrusions, grooves, clipping areas) that guide segments into precise circular arrangement while simplifying the assembly process.
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
The solution enhances the reproducibility and speed of winding, improves the structural integrity of the motor, and simplifies the manufacturing process by providing precise alignment and protection of the laminated core, resulting in improved production quality and reduced manufacturing complexity.
Implementation Method 1
the radially protruding retaining ring sections act as lubricants during insertion into the recess, as the retaining ring essentially acts as a lubricant reservoir, providing sufficient lubricant during assembly
Data Source
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AI summary
Electric motor, having a stator which is composed of individual segments arranged in the circumferential direction, with each individual segment having a laminated core around which a winding is provided and on the axial end areas of which end caps are provided, wherein the winding is produced by means of a winding wire, wherein an end cap has at least one dome, in particular in order to bound the area of the winding, wherein a wire inlet channel for changing the direction of the winding wire is provided in the foot area of the dome, wherein grooves are provided on the end cap, wherein the distance between one groove and the radially closest groove and the diameter of curvature of the respective groove are less than the winding wire diameter.