Segmented Stator Assembly with Interlocking Connectors
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Solution Overview
Problem
Existing stator designs for rotary electric machines face challenges in achieving high insulation reliability and efficient winding operations due to complex geometries and variations in assembly, leading to inconsistencies in winding patterns and insulation distribution.
Innovation Solution
A segmented stator assembly is created using stamped steel laminations with interlocking tabs and detents, overmolded with insulating material to form posts and end caps, and connected with specialized connectors that facilitate seamless wire winding and insulation between segments, allowing for efficient assembly and reduced variation in insulation distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex geometries and variations in assembly are used in existing stator designs, then the stator can accommodate different winding patterns and insulation distributions, but the insulation reliability and winding consistency deteriorate due to assembly inconsistencies
Solution Approach 1:
The stator is divided into multiple stator segments that are assembled together to form the complete stator assembly. Each segment contains pre-positioned insulation structures and winding patterns, which are then joined using connectors. This segmentation allows for standardized, repeatable assembly processes that maintain insulation reliability while accommodating different winding configurations through the arrangement of individual segments.
2Adaptability or versatility
If complex geometries and variations in assembly are used in existing stator designs, then the stator can accommodate different winding patterns and insulation distributions, but the winding consistency deteriorates due to assembly variations
Solution Approach 1:
The stator is divided into multiple stator segments that are assembled together to form the complete stator assembly. Each segment contains pre-positioned insulation structures and winding patterns, which are then joined using connectors. This segmentation allows for standardized, repeatable assembly processes that maintain insulation reliability while accommodating different winding configurations through the arrangement of individual segments.
Solution Approach 2:
Connectors are introduced as intermediary components to join the stator segments together. These connectors ensure precise alignment and consistent positioning of adjacent segments, thereby maintaining winding consistency across the entire stator assembly while allowing for different winding patterns within each segment.
3Device complexity
If traditional stator assembly methods are used, then the assembly process can handle complex geometries, but the assembly complexity and time increase
Solution Approach 1:
The stator is divided into multiple stator segments that can be manufactured independently and then assembled using standardized connectors. This segmentation simplifies the manufacturing of each individual segment while enabling efficient assembly of the complete stator, thereby improving productivity without sacrificing the ability to handle complex geometries.
Solution Approach 2:
The connectors designed for joining stator segments are universal components that can accommodate different segment configurations and winding patterns. This universality allows the same connector design to be used across various stator assemblies, simplifying the assembly process and improving efficiency while maintaining the capability to handle complex geometries.
Data Source
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AI summary
A stator has a plurality of segments connected with connectors to define a core for the stator. Each of the segments comprises a plurality of laminations arranged side by side forming a lamination stack with axially opposite sides. The lamination stack has an end cap abutting an axial side of the lamination stack. The end cap has first and second posts extending axially therefrom. At least one of the posts defining a wire path for wire wound around the stack. Each of the connectors comprises a bridge portion. The bridge portion has openings dimensioned to receive the posts in a manner that the connector is removably attachable to the post of the end cap of a segment and the post of the end cap of an adjacent segment. The connector has an insulator portion projecting from the bridge portion. The insulator portion extends between adjacent segments when the connector is removably attached to adjacent segments.