Segment Coil Stator Assembly With Collective Insertion Inspection
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Solution Overview
Problem
The existing stator manufacturing method requires repetitive insertion and resistance measurement for each pair of segment coils into the stator core slots, increasing the number of steps in the assembly process.
Innovation Solution
The method involves inserting lead-side and lead-opposite-side segment coils covered with insulating films into slots, forming holes in the films to create exposed conductor portions while inserted, allowing collective insertion and inspection via resistance measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resistance measurement is performed for each pair of segment coils inserted into slots, then electrical connection inspection is ensured, but the number of assembly steps increases
Solution Approach 1:
The patent combines multiple resistance measurement operations into a single collective measurement process. By providing a common measurement device that can simultaneously measure multiple segment coils, the patent merges what were previously separate inspection steps into one unified operation, thereby reducing the total number of assembly steps while maintaining reliable electrical connection inspection.
Solution Approach 2:
The measurement device is designed with multi-functionality to handle multiple segment coils simultaneously. This universal device can perform resistance measurements on several coils in parallel, eliminating the need for separate measurement devices or repeated measurement operations for each coil pair, thus simplifying the overall assembly process.
2Manufacturing precision
If segment coils are inserted from outer circumference toward inner circumference, then proper positioning is achieved, but repetitive insertion and inspection steps are required
Solution Approach 1:
The patent applies preliminary action by providing guide structures (such as guide grooves or guide protrusions) that pre-position the segment coils correctly during insertion. This preliminary positioning guidance ensures that coils are properly oriented and positioned from the start, eliminating the need for repeated insertion and inspection cycles to achieve correct positioning, thereby improving assembly efficiency.
Data Source
AI summary
A stator manufacturing method includes an inserting step of inserting lead-side segment coils covered with an insulating film and lead-opposite-side segment coils covered with an insulating film into a plurality of slots formed between a plurality of teeth radially protruding from an annular yoke, along the axial direction of the yoke, and electrically connecting the segment coils by using connecting members, in the inserting step, the plurality of segment coils are collectively inserted into the slots, and the method further includes an exposing step of forming the segment coils with exposed conductor portions by forming holes penetrating the insulating films in crossover parts of the segment coils while the segment coils are inserted in the slots.