Segment Core Stator Winding via Groove Hole Positioning
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Solution Overview
Problem
The existing method of manufacturing stators for outer rotor type motors involves multiple bending processes, leading to increased man-hours, deformation, and positional displacement, which results in a loss of roundness and reduced productivity due to the need for manual winding and limited space for automatic winding machines.
Innovation Solution
The stator is manufactured using segment cores with groove holes for positioning, allowing for automatic winding with a high space factor by forming the cores in an annular shape while maintaining roundness, and using concave-convex fitting to connect the segments, ensuring accurate assembly and reduced curvature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the stator core is formed with many slots and narrow gaps between teeth edges, then the motor can achieve higher power density, but automatic winding becomes impossible and manual winding must be used
Solution Approach 1:
The stator core is divided into multiple segment cores that can be assembled together. Each segment core has a smaller number of slots with wider gaps between teeth edges, enabling the winding machine nozzle to enter and perform automatic winding. After winding, the segment cores are assembled to form the complete stator core with the required number of slots, thus achieving both high power density and automatic winding capability.
2Ease of manufacture
If the core members are bent multiple times to form the annular shape, then the stator can be assembled, but the thin wall parts deform and positional displacement occurs, losing roundness
Solution Approach 1:
The segment cores are pre-formed with groove holes positioned at both end parts in a longitudinal direction. These groove holes serve as positioning features that prevent deformation and positional displacement during the bending and assembly processes. By establishing positioning structures in advance, the roundness of the stator core is maintained while enabling assembly.
3Manufacturing precision
If positioning groove holes are formed in the yoke parts, then the segment cores can be accurately positioned during assembly, but the manufacturing complexity increases
Solution Approach 1:
The groove holes are formed in the yoke parts of each segment core separately during the segment core manufacturing process. This segmentation approach allows the groove holes to be integrated into the segment core production without requiring additional complex positioning equipment for the entire stator. The positioning features are created as part of the normal segment core fabrication, minimizing additional manufacturing complexity while achieving accurate positioning.
Data Source
AI summary
Groove holes capable of positioning each of the segment cores with respect to a winding jig in an arc attitude with wide gaps between the teeth edges of respective pole teeth are respectively formed in yoke parts positioned at both end parts of each of the segment cores in a longitudinal direction.