Segmented Stator Needle Winding for High Copper Fill
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Solution Overview
Problem
Existing methods for winding coils on stator teeth in electric motors result in inefficient use of space between teeth due to the need to accommodate a winding needle, leading to compromised motor performance and power output.
Innovation Solution
A method and apparatus for forming a segmented stator using a winding nest and tool that allows for thicker needles and more robust winding, enabling the segments to be collapsed together with increased wire fill, thus reducing gaps between teeth and enhancing copper fill density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a winding needle is used to wind coils on stator teeth, then the winding operation can be performed, but the needle occupies space between teeth reducing copper fill density
Solution Approach 1:
The stator is divided into multiple tooth segments that can be separated during the winding process. This segmentation allows the winding needle to access teeth from the outside rather than requiring space between tightly packed teeth, enabling higher copper fill density while maintaining ease of winding operation.
Solution Approach 2:
The winding operation transitions from a two-dimensional space constraint (needle fitting between teeth in the same plane) to a three-dimensional approach where tooth segments are separated radially. This dimensional change allows the needle to wind coils without occupying space between teeth, resolving the contradiction between manufacturability and copper fill density.
2Quantity of substance
If tooth segments are positioned close together to maximize copper fill, then motor power output increases, but the winding needle cannot access the teeth for coil winding
Solution Approach 1:
The tooth segments are made dynamically positionable between a closed configuration (close together for maximum copper fill) and an open configuration (separated for needle access). This dynamic reconfigurability allows the system to optimize for copper fill density during operation while maintaining ease of manufacture during the winding process.
Solution Approach 2:
The tooth segments are preliminarily separated before the winding operation to provide needle access, then brought together after winding to achieve maximum copper fill density. This preliminary action sequence resolves the contradiction by preparing the structure for manufacturing before optimizing for performance.
3Reliability
If a thick winding needle is used for robust winding, then winding reliability improves, but the space occupied by the needle increases reducing copper fill
Solution Approach 1:
The winding needle is extracted from the space between teeth and positioned to wind from the outside of the tooth segments. This extraction eliminates the space occupation problem, allowing a thick, reliable needle to be used without reducing copper fill density, as the needle no longer competes for space between the teeth.
Data Source
AI summary
A segmented stator for an electric motor comprises: a plurality of tooth segments arranged in a circular configuration, the tooth segments having body portions and front surfaces extending inward from the body portions; and wire wound on the body portions. A distance between adjacently positioned front surfaces of the tooth segments is less than a width of the wire. The wire wound on the body portions substantially fills space between adjacently positioned tooth segments.