Stator Coil Carrier Layout for Compact Axial Connection Contacts
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Solution Overview
Problem
Conventional stators have a radial projection that increases the diameter, making them unsuitable for tight installation spaces, particularly in applications like motor vehicle oil pans.
Innovation Solution
A stator design with a coil carrier having guide grooves and axial connection contacts within the stator's outer contour, allowing for a compact winding process with minimal radial dimensions and reduced crossing points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If connection contacts are arranged on a radial projection extending outwards from the stator core, then the connection contacts can be easily accessed and connected, but the diameter of the stator increases, requiring more installation space in the radial direction
Solution Approach 1:
The connection contacts are arranged in the axial direction within the ring-shaped outer contour of the coil carrier, transitioning from radial arrangement to axial arrangement. This dimensional change allows connection contacts to be accessible while maintaining compact radial dimensions, as the contacts are positioned at different axial levels rather than extending radially outward.
Solution Approach 2:
The connection contacts are nested within the ring-shaped outer contour of the coil carrier, utilizing the internal space of the coil carrier structure. This nesting approach allows the connection contacts to be housed within the existing stator boundary rather than extending beyond it, thereby reducing the required radial installation space.
2Ease of manufacture
If a radial projection is used to accommodate connection contacts, then the connection contacts can be mounted, but additional installation space in the radial direction is required
Solution Approach 1:
The connection contacts are positioned in the axial direction within the coil carrier's ring-shaped contour, changing from radial mounting to axial mounting. This allows connection contacts to be manufactured and mounted using standard axial processes while eliminating the need for additional radial installation space.
Solution Approach 2:
The coil carrier serves multiple functions: it supports the coils, provides structural integrity to the stator, and houses the connection contacts within its ring-shaped outer contour. This multi-functionality eliminates the need for separate radial projections, reducing the overall radial footprint while maintaining ease of manufacture.
3Ease of operation
If winding wire routing requires many crossing points, then connection between coils and connection contacts becomes complex, but the radial dimensions increase and compact design is compromised
Solution Approach 1:
The winding wire is routed primarily in the axial direction and circumferential direction within the coil carrier, avoiding radial crossings. By utilizing the axial dimension and circumferential paths, the wire routing achieves clear paths with minimal crossing points, maintaining compact radial dimensions while simplifying the routing operation.
Data Source
AI summary
A stator for an electric motor includes a stator core with a plurality of teeth, a coil for each tooth, and a coil carrier which is arranged on the stator core. The coil carrier has a plurality of guide grooves for a winding wire which forms the coils, and three receptacles for connection contacts, which extend in the axial direction of the stator and lie within the ring-shaped outer contour of the coil carrier. A connection contact is arranged in each receptacle and is electrically connected to the winding wire.