Split Core Stator Assembly with Conductor Holders
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Solution Overview
Problem
Conventional split core type stators face difficulties in accommodating distributed winding coils due to the challenge of bending deformation and uneven wire disposition, making it hard to automate the insertion of in-slot conductor portions into slots, which can damage insulating coats and require skilled labor.
Innovation Solution
A method involving a coil preparing step, split core disposing step, teeth inserting step, and split core joining step, where conductor holders displaceably support in-slot conductor portions to maintain alignment and facilitate smooth insertion by moving in conjunction with split cores, ensuring even distribution and preventing deviation during the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If distributed winding coil with large cross-sectional area electric wires is used, then the stator coil can be made in cylindrical shape to facilitate insertion, but the electric wires cannot be evenly disposed along the circumferential direction and require skilled work
Solution Approach 1:
A guide member is introduced as an intermediary component during the assembly process. The guide member temporarily guides the in-slot conductor portions into the slots of split cores, enabling automated assembly. After insertion, the guide member is removed, leaving the conductor portions properly positioned without requiring skilled manual work.
Solution Approach 2:
The guide member is prepared in advance and positioned to anticipate the insertion path of the conductor portions. By pre-positioning the guide member, the system enables automated insertion without requiring real-time skilled adjustment during the assembly process.
2Manufacturing precision
If in-slot conductor portions are squeezed into slots to increase slot lamination factor, then the circumferential width matches the slot width, but the insulating coat resin film may be damaged
Solution Approach 1:
The guide member acts as a cushioning element that prevents direct contact and squeezing between the conductor portions and the slot walls. By providing this protective interface in advance, the insulating coat resin film is protected from damage while still achieving proper insertion and slot lamination.
3Ease of operation
If conventional split core type stator is used with concentrated winding stator coil, then the work to insert in-slot conductor portions is facilitated, but distributed winding coil with large cross-sectional area electric wires is difficult to wind
Solution Approach 1:
The guide member serves as a mediator that enables the insertion of distributed winding coils, which have larger cross-sectional areas and are more difficult to insert. This intermediary component makes the insertion process as easy as conventional concentrated winding insertion while allowing the use of distributed winding coils for improved performance.
Data Source
AI summary
A method of manufacturing a stator coil including shaping a plurality of shaped bodies from electric conductor wires; combining the shaped bodies to form a combined body; and winding the combined body around a core member to form a wound body. The shaped body includes a plurality of parallel straight portions extending along a longitudinal direction of the combined body, and a plurality of turn portions connecting straight portions at ends of the straight portions in an alternating manner. Each of the shaped bodies includes a plurality of straight overlap sections. The wound body includes a plurality of straight laminated sections formed from the plurality of straight overlap sections laminated in a radial direction. Pre-orientation members are inserted respectively into consecutive clearances formed between adjacent straight overlap sections during the winding step, so overlap of the straight portions in the straight overlap section caught between said pre-orientation members is aligned.