Segmented Stator Winding with Radial Connecting Wire
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Solution Overview
Problem
Existing stator manufacturing methods require additional assembly steps and tools for connecting wires between partial coils, leading to increased wiring effort and axial space usage, which complicates the assembly process and reduces efficiency.
Innovation Solution
The method involves arranging separately manufactured stator segments with fully wound uninterrupted partial coils directly next to each other, routing the connecting wire radially through insulating masks, which eliminates the need for additional assembly steps and reduces axial space, allowing the stator segments to be pivoted as a joint-like connection, enabling efficient winding and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connecting wires are arranged axially above partial cores and pressed axially outwards, then the partial coils are connected, but additional assembly tools and assembly steps are required
Solution Approach 1:
The connecting wire is pre-integrated into the insulating mask during the insulating mask formation process, rather than being added separately during assembly. This preliminary integration eliminates the need for additional assembly tools and steps while ensuring reliable connection between partial coils
Solution Approach 2:
The connecting wire and insulating mask are merged into a single integrated component. The insulating mask serves dual functions: providing electrical insulation and housing the connecting wire that joins partial coils, thereby reducing assembly complexity while maintaining connection reliability
2Reliability
If connecting wires are pressed axially outwards, then the partial coils are connected, but axial space is consumed
Solution Approach 1:
The connecting wire is routed radially through the insulating mask instead of being pressed axially outwards. This dimensional change from axial to radial arrangement reduces the axial length of the stator while maintaining reliable electrical connection between partial coils
3Ease of manufacture
If separately manufactured stator segments are assembled, then manufacturing flexibility is improved, but wiring effort increases
Solution Approach 1:
The connecting wire is pre-installed in the insulating mask before stator segment assembly. This preliminary action allows separate manufacturing of stator segments to proceed efficiently without subsequent wiring operations, maintaining manufacturing flexibility while eliminating additional wiring effort
Solution Approach 2:
The insulating mask with integrated connecting wire serves itself by providing both insulation and electrical connection functions. This self-service approach eliminates the need for separate wiring operations after assembly, improving productivity while preserving manufacturing flexibility
Data Source
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AI summary
The invention relates to a stator (12) and to a method for producing a stator (12), on which a plurality of electrical phase windings (40) having individual coil sections (15) are disposed, characterised by the following steps: manufacturing a plurality of separate stator segments (14), winding a first stator segment (16) with a first coil section (17), winding a second stator segment (18) with a second coil section (19) with a wound uninterrupted coil wire (44), disposing the first and second stator segments (16, 18) immediately adjacent to one another in the circumferential direction (31) of the stator (12), disposing further stator segments (20) in a circle (24), mechanically connecting the individual stator segments (16, 18, 20).