Rotating Electrical Machine Lap Winding Coil Insertion
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Solution Overview
Problem
The existing methods for manufacturing rotating electrical machines with lap winding are inefficient due to the low flexibility of coils, which increases man-hours and reduces productivity when dealing with coils of different slot pitches, requiring multiple divisions and insertions.
Innovation Solution
The solution involves creating unit coils with different slot pitches and forming coil groups that are inserted into the stator slots in a lap winding configuration, with each group having the same arrangement configuration but shifted by a predetermined slot pitch, allowing for improved flexibility and reduced man-hours during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If coils are divided into multiple groups and inserted stepwise, then operability of coil insertion is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The patent applies segmentation by dividing the stator winding into multiple independent coil groups, where each group can be manufactured and inserted separately. This allows the winding process to be performed in parallel across multiple stations or by multiple workers simultaneously, reducing total manufacturing time while maintaining the stepwise insertion approach that improves operability
Solution Approach 2:
The patent implements preliminary action by pre-assembling complete coil groups with all necessary connections and configurations before insertion into the stator. Each coil group is prepared in advance with standardized structures, allowing for rapid insertion without requiring complex on-site assembly operations, thereby reducing manufacturing time
2Adaptability or versatility
If multiple types of unit coils with different slot pitches are used, then adaptability to different stator configurations is improved, but device complexity increases
Solution Approach 1:
The patent applies universality by designing a standardized coil group structure that can accommodate multiple types of unit coils with different slot pitches within the same group. The coil group framework is universal and can be configured to include various combinations of unit coils, allowing a single coil group design to serve multiple stator configurations without requiring entirely different group structures
Solution Approach 2:
The patent implements local quality by allowing different unit coils within a coil group to have specific properties tailored to their local requirements (different slot pitches), while the overall coil group maintains a standardized structure. This enables customization at the unit coil level without compromising the universality of the entire coil group system
Data Source
AI summary
A rotating electrical machine includes a stator and a rotor rotatably mounted on the stator. The stator includes a plurality of slots into which coils are insertable, a plurality of types of unit coils inserted into the slots at slot pitches differing for every type of unit coil, and a plurality of coil groups formed by arranging the unit coils in a lap winding so that the unit coils are overlapped in a radial direction of the stator. The coil groups have the same arrangement configuration before insertion into the slots and are inserted into the slots so as to be shifted from each other by a predetermined slot pitch.