Segmented Stator Coil Assembly for Low Torque Ripple Motors
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Solution Overview
Problem
Existing stator manufacturing methods for electric motors face issues such as increased noise and vibrations due to torque ripple phenomena, low filling factor of conducting wires, and inefficiencies in motor performance, which result in reduced efficiency and increased axial volumes.
Innovation Solution
A method and processing line for manufacturing stators that involves winding conducting wires into coils with linear portions, inserting these coils between stator teeth, and deforming the stator components to optimize coil placement, thereby improving the filling factor and reducing torque ripples through a combination of coil housing, shaping, and assembling steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the slot opening is increased to facilitate coil insertion, then the ease of manufacture is improved, but the torque ripple phenomena increase causing noise and vibrations
Solution Approach 1:
The patent applies preliminary action by pre-forming the coil with a specific configuration that includes a linear portion and curved portions before insertion. The coil is prepared in advance with the exact shape needed to fit into the stator slot, eliminating the need for large slot openings. The linear portion of the coil is inserted first, followed by deformation to achieve the final position, allowing precise control over the insertion process without increasing the slot opening.
Solution Approach 2:
The patent segments the coil into distinct portions: a linear portion for insertion and curved portions for final positioning. This segmentation allows the coil to be inserted through a smaller slot opening using the linear portion, while the curved portions are subsequently deformed into place. The stator assembly is also segmented into individual teeth that can be independently positioned and deformed during the manufacturing process.
2Ease of manufacture
If the distance between pole shoes is increased to facilitate manufacturing, then the ease of manufacture is improved, but the noise phenomena increase
Solution Approach 1:
The patent applies preliminary action by pre-assembling the stator teeth and coils in a controlled manner before final deformation. The teeth are positioned with appropriate spacing during the assembly phase, and the coils are pre-formed to match these dimensions. Only in the final deformation step are the teeth brought closer together, ensuring optimal spacing from the beginning rather than requiring larger initial gaps for manufacturing access.
3Power
If the filling factor of sectors is increased by inserting more conducting wires, then the power is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-forming the coil with multiple conducting wires arranged in a specific pattern before insertion. The linear portion of the coil is prepared in advance with the exact configuration needed, including the arrangement of multiple wires to achieve high filling factor. This pre-arrangement ensures precise wire positioning during insertion, eliminating the need for complex post-insertion alignment operations.
Solution Approach 2:
The patent merges multiple conducting wires into a single integrated coil structure with a linear portion. Instead of inserting individual wires separately, which would require high manufacturing precision for each wire's position, the wires are combined into one cohesive component that is inserted as a unit. This merging simplifies the manufacturing process while maintaining the high filling factor achieved through the combined wire structure.
4Volume of moving object
If the axial volume of stators is reduced for compactness, then the volume is improved, but the ease of operation during assembly worsens
Solution Approach 1:
The patent applies preliminary action by pre-deforming the stator teeth and positioning the coils before final assembly. The teeth are prepared with the appropriate geometry and spacing in advance, and the coils are pre-formed to match these dimensions. This preliminary preparation allows the final assembly to be completed in a compact configuration without requiring complex manipulation during the assembly process itself.
Solution Approach 2:
The patent applies dynamics by using a deformation process that transforms the stator components from an initial accessible configuration to a final compact configuration. During the deformation step, the teeth are gradually brought closer together while the coils are simultaneously positioned, allowing the structure to transition dynamically from a state suitable for assembly to a compact final state. This dynamic approach enables compact axial dimensions while maintaining ease of operation during the transformation process.
Data Source
AI summary
A method, a processing line and components of the processing line for making a stator for electric motors, and the resultant stator. The conducting wire is wound in coils having at least one straight portion which is inserted into a corresponding stator sector. The sector is thus deformed to move its teeth close to each other and to close the straight portion of the coil. Multiple stator sectors so made are assembled together to form a stator complete with windings. During the production of stator sectors, the coils and/or stator sectors are rototranslated to bring them to the final position they must take inside the finished stator. Measures are provided to maximize the filling factor, to minimize torque ripple phenomena, to minimize noise and the vibrations of the electric motor achieved with the stator, and to maximize its performance, under other equal conditions.