Slotless Motor Stator Folding Layout to Cut Assembly Time and Losses
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Solution Overview
Problem
Existing methods of manufacturing slotless motors are time-consuming and costly, and often require multiple steps to join individual conductor coils or result in disorganized conductor loops leading to circulating losses.
Innovation Solution
A method involving bonding and folding conductor lengths to form a stator, using a bonding compound to create bonded lengths with smaller spacing, and rotating petals to align parallel bonded lengths around a central axis, reducing the need for welding and minimizing circulating losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual conductor coils are joined together after shaping to form a stator, then the stator can be assembled from pre-formed coils, but the manufacturing process becomes time-consuming and costly due to multiple joining operations
Solution Approach 1:
The patent combines multiple conductor coils into a single continuous conductor that is folded and bonded to form the stator winding. This eliminates the need for separate joining operations between individual coils, as the conductor forms an integrated structure through bonding at specific lengths along its path.
Solution Approach 2:
The conductor is prepared in advance as a single continuous piece with predetermined bonding lengths marked or configured. This preliminary preparation allows the conductor to be directly folded and bonded into the final stator configuration without requiring subsequent joining operations, thereby reducing manufacturing time.
2Loss of time
If a single conductor is compressed into a given shape to form loops, then the number of joining operations is reduced, but the conductor loops become disorganized with crossing and non-parallel arrangements resulting in circulating losses
Solution Approach 1:
The patent applies bonding to specific local lengths of the conductor rather than uniformly throughout. These bonded lengths create localized rigid sections that maintain parallel orientation and prevent crossing, while non-bonded sections allow for the necessary folding and shaping. This selective local bonding ensures organized loop formation without circulating losses.
Solution Approach 2:
The conductor is divided into distinct bonded lengths and non-bonded lengths along its path. The bonded lengths provide structural stability and maintain parallel orientation, while the non-bonded lengths provide flexibility for folding and shaping. This segmentation allows the conductor to be formed into organized loops without crossing or disorganization.
3Ease of manufacture
If multiple joining operations are performed to connect conductor coils, then the stator structure can be assembled from individual coils, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple conductor coils into a single continuous conductor structure that is folded and bonded in place. This eliminates the need for separate joining operations and reduces device complexity by creating an integrated winding structure rather than assembling discrete components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces manufacturing time and costs while enhancing conductor density, reducing power losses, and improving power transfer between the stator and rotor.
Implementation Method 1
bonding a plurality of bonded lengths on the conductor wherein the bonded lengths comprise regions of the conductor wherein adjacent wires are bonded along the bonded lengths
Data Source
AI summary
The present disclosure is directed to slotless electric motor, in particular, to a method of manufacturing a stator for a slotless electric motor. An aspect of the disclosure provides a method of manufacturing a stator for a slotless electric motor, the method comprising: disposing a conductor in the shape of an annular cylinder; bonding a plurality of bonded lengths of the conductor, wherein the plurality of bonded lengths are separated by non-bonded lengths; folding the conductor to provide a plurality of petals repeated along the conductor, wherein each petal comprises a pair of bonded lengths connected by a non-bonded length; rotating each petal about a point on the second circle to align in parallel the bonded lengths of all of the petals to thereby provide a stator comprising a cylindrically-shaped conductor wherein the bonded lengths are equidistantly disposed around and from a central longitudinal axis of the cylindrically-shaped conductor.