Segmented Stator Assembly With Single Coil Support
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Solution Overview
Problem
Existing stators are difficult to miniaturize due to space constraints and manual manipulation challenges, hindering efficient manufacturing and automation.
Innovation Solution
A segmented stator design featuring a single coil support with radially inserted stator segments and coils, allowing for easier assembly and automation through a common coil support that holds all coils, facilitating winding and insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coils are wound directly on pole teeth or on individual coil supports, then the stator can be assembled with multiple components, but the manufacturing process becomes complex and difficult to automate
Solution Approach 1:
The patent merges all coil supports into a single integrated component that holds multiple coils simultaneously. This single coil support replaces what would otherwise be multiple separate coil supports, simplifying the overall assembly structure while maintaining the ability to wind all coils in one operation. The merged design eliminates the need for multiple separate winding operations and reduces the number of parts that need to be assembled.
Solution Approach 2:
The patent implements preliminary action by providing a pre-configured single coil support structure that is designed to hold all coils in their final positions before assembly. The coil support is prepared in advance with appropriate features for holding coils and for radial insertion of stator segments, enabling all coils to be wound simultaneously in a preliminary manufacturing step before the final assembly operation.
2Ease of operation
If stator segments are inserted axially, then assembly can be simplified, but space for manipulation and automation is reduced
Solution Approach 1:
The patent inverts the conventional axial insertion approach by implementing radial insertion of stator segments into the coil supports. Instead of inserting segments from the ends along the axial direction, the segments are inserted radially from the outer periphery toward the center. This inversion provides significantly more manipulation space for automated assembly equipment and improves accessibility for both manual and automated operations.
3Manufacturing precision
If multiple individual coil supports are used, then each coil can be supported separately, but winding time increases and automation becomes more difficult
Solution Approach 1:
The patent merges multiple individual coil supports into a single integrated coil support structure that can hold and position multiple coils simultaneously. This merged design maintains precise positioning for each coil through dedicated holding features within the unified structure, while enabling all coils to be wound in one continuous operation, thereby dramatically improving productivity and facilitating automated manufacturing.
Data Source
AI summary
A segmented stator for an electric motor, the segmented stator comprising at least one coil support, at least two coils attached to the at least one coil support and each comprising a coil hollow portion, at least two stator segments, such as lamination stacks. Each stator segment comprises a pole tooth protruding toward a centre of the segmented stator and inserted in one of the coil hollow portions and/or in the at least one coil support. Adjacent stator segments are attached or locked to each other one by one, preferably with at least one pin. The at least one coil support is integral, and the stator segments are distinct from the at least one coil support.