Segmented Stator Winding Assembly to Prevent Turn-To-Turn Failures
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Solution Overview
Problem
Current stator manufacturing methods for electric aircraft motors face challenges in efficiently creating modular winding sets and installing teeth segments, which can lead to inefficiencies and potential turn-to-turn failures in electric motors.
Innovation Solution
A manufacturing apparatus and method that includes a work-holding device, a winding device to create modular winding sets by winding a continuous conductor on each tooth, and an installation device to securely integrate the segments into the stator, using a computing device to control the process and prevent turn-to-turn failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual teeth are wound then soldered or joined to create multiple phase segments, then the stator can be manufactured, but the process leads to inefficiencies and potential turn-to-turn failures
Solution Approach 1:
The stator is divided into multiple segments that are manufactured separately and then assembled together. Each segment contains teeth with windings that are created using continuous conductor before assembly, eliminating the need for soldering or joining operations between individual teeth while maintaining manufacturing efficiency.
Solution Approach 2:
The windings are created on the teeth using continuous conductor before the segments are assembled into the final stator structure. This preliminary winding action prevents turn-to-turn failures that would occur with post-assembly soldering or joining operations.
2Productivity
If traditional winding methods are used on individual teeth, then manufacturing can proceed, but the process is time-consuming and prone to errors
Solution Approach 1:
Multiple winding operations are merged into a single continuous conductor process. The continuous conductor passes through multiple teeth in sequence, creating all windings in one operation rather than separately winding each tooth, which increases both speed and consistency.
Solution Approach 2:
The winding process uses continuous conductor that maintains uninterrupted flow through all teeth during the winding operation. This continuity eliminates stopping and starting between teeth, improving manufacturing speed and ensuring consistent winding tension and quality throughout all segments.
Data Source
AI summary
An apparatus for manufacturing a stator for an electric aircraft motor includes a manufacturing device. The manufacturing device includes a work holding device configured to hold at least one segment of teeth. The manufacturing device also includes a winding device configured to create a modular winding set in the at least one segment of teeth. Creating the modular winding set includes acquiring a continuous conductor and winding a continuous conducting coil on each tooth of the plurality of teeth held by the work holding device using the continuous conductor. The manufacturing device may also include an installation device configured to install a plurality of segments of teeth into the stator.