Electric Motor Winding on End Plate
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Solution Overview
Problem
Existing methods for manufacturing electric motor stators are complex, require multiple parts and orientations, leading to increased production time and quality risks due to the need for swiveling needles and additional insulation.
Innovation Solution
A simplified winding method and electric motor design where the entire wiring of coil windings is carried out on an end disk, eliminating the need for swiveling needles and using a central end plate with contact hooks for parallel movement, reducing the complexity and number of parts required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a swiveling needle is used for winding, then the needle can reach different positions, but the device complexity increases and production time increases due to folding operations
Solution Approach 1:
The winding process is segmented into multiple passes, with the needle performing only simple radial and axial movements in each pass. The stator is rotated between passes to present different winding zones to the needle, eliminating the need for complex swiveling mechanisms while achieving complete coverage.
Solution Approach 2:
The system transitions from a static needle requiring complex swiveling to a dynamic system where the stator rotates to bring different areas under the needle. This dynamic approach simplifies the needle mechanism while maintaining full winding capability.
2Reliability
If additional surface insulation is added for wire routing, then insulation strength improves, but the device complexity and manufacturing steps increase
Solution Approach 1:
The insulation function is extracted from a separate surface insulation layer and integrated into the end plate structure itself. The end plate, being an insulating component anyway, is designed to provide both mechanical support and electrical insulation, eliminating redundant insulation layers and simplifying manufacturing.
3Productivity
If grippers are used to pull out winding wire radially, then the winding process can proceed, but the device complexity increases and additional parts are required
Solution Approach 1:
The winding wire is fed through a guide at the needle and naturally exits in the radial direction due to the winding geometry and tension, eliminating the need for active grippers to pull the wire. The system uses the inherent mechanics of the winding process to achieve wire deployment.
4Volume of moving object
If the needle folds during winding, then space utilization improves, but production time increases due to time spans required for folding
Solution Approach 1:
Instead of folding the needle in-plane to change position, the solution uses the third dimension by rotating the stator to present different winding zones to the stationary needle. This dimensional change eliminates folding operations while maintaining space utilization efficiency.
Data Source
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AI summary
Electric motor, comprising a stator and its coil windings, and winding method, wherein the wiring of the coil windings can be implemented on an end plate.