Quadrangular Stator Coil Installation with Differential Restraint
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Solution Overview
Problem
Existing coil installation methods for rotary electric machines often result in coils interfering with the stator core or adjacent coils, leading to hindered smooth installation due to excessive restraint and lack of flexibility.
Innovation Solution
A coil installation method and jig that form a generally quadrangular coil with overlapping winding portions, where the innermost and outermost peripheral winding portions are restrained in the circumferential direction, allowing the intermediate portions to move freely and be deformed to prevent unnecessary displacement during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the coil is restrained in all directions during installation, then the coil shape is maintained, but the installation smoothness is reduced due to excessive restraint
Solution Approach 1:
The holding portions are divided into multiple segments: first holding portions that restrain the innermost and outermost peripheral winding portions, and second holding portions that allow intermediate winding portions to move freely in the circumferential direction. This segmentation enables differential restraint across different parts of the coil, maintaining shape stability while permitting installation flexibility.
Solution Approach 2:
Different regions of the coil are given different restraint characteristics: the innermost and outermost peripheral winding portions are restrained in the circumferential direction to maintain overall coil shape, while the intermediate winding portions are allowed to move freely to facilitate smooth installation and accommodate interference with insulators or adjacent coils.
2Ease of operation
If the coil is deformed to fit between teeth, then the installation is enabled, but the coil may twist or deform excessively
Solution Approach 1:
The coil is pre-formed with a quadrangular shape having winding portions with appropriate widths before installation. The outer peripheral winding portions are designed with larger widths than inner peripheral portions, anticipating the deformation needed for installation between teeth while maintaining controllability during the process.
Solution Approach 2:
The holding portions are configured to dynamically adapt during installation: they restrain the coil at critical points (innermost and outermost portions) to prevent excessive twisting, while allowing controlled deformation of intermediate portions to enable the coil to fit between the teeth.
Data Source
AI summary
A coil installation method for installing a coil on a tooth of a stator core to manufacture a stator for a rotary electric machine, the coil installation method including forming the coil such that a rectangular wire is wound into a generally quadrangular shape so as to form three or more winding portions overlapping in a radial direction of the stator core and such that the winding portion positioned on an outer peripheral side in the radial direction has a larger width directed in a circumferential direction of the stator core.