Stator Bus Bar Overlap Reduces Winding Complexity
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Solution Overview
Problem
The existing motor stator winding processes are complex and time-consuming, requiring multiple wire connections to bus bars, which increases production complexity and cost.
Innovation Solution
A stator design featuring overlapping end parts of the bus bars and a transition line system that allows for simplified assembly by connecting the bus bars through a single operation, reducing the radial and axial size of the stator and motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple wires are used to wind multiple teeth of corresponding phases and connect to bus bars separately, then the winding can be completed, but the process becomes complex and time-consuming
Solution Approach 1:
The patent merges multiple separate wire connections into a single integrated bus bar structure. The bus bar is designed with multiple connection points that can simultaneously connect to multiple coil groups, eliminating the need for separate wire connections for each phase. This merging of connection functions into a single component directly reduces process complexity while maintaining manufacturing capability.
Solution Approach 2:
The bus bar is pre-formed with specific geometric features including overlapping end parts and connection surfaces before assembly. The overlapping end parts are prepared in advance to enable direct connection to multiple coils during a single assembly operation. This preliminary preparation of the bus bar structure eliminates the need for complex on-site wiring operations.
2Productivity
If multiple wires are used to wind and connect to bus bars, then the winding can be completed, but the production time increases
Solution Approach 1:
Multiple connection operations are merged into a single bus bar assembly operation. The bus bar structure allows simultaneous connection to multiple coil groups in one operation, dramatically reducing the number of discrete connection steps required and thereby reducing total production time.
Solution Approach 2:
The bus bar is pre-assembled with all necessary connection surfaces and overlapping end parts before motor assembly. This preliminary preparation enables rapid connection to multiple coils during final assembly, eliminating time-consuming on-site wiring operations and improving overall production efficiency.
3Ease of operation
If the bus bars are connected through separate operations for each end part, then the connection can be made, but the assembly process becomes complex
Solution Approach 1:
The bus bar design merges the connection of multiple end parts into a single integrated structure. The overlapping end parts are positioned and connected simultaneously during one assembly operation, eliminating the need for separate connection operations for each end part and simplifying the overall assembly process.
Solution Approach 2:
The bus bar overlapping end parts are arranged in a nested configuration where one end part overlaps with another in the axial direction. This nesting arrangement allows multiple connections to be made in a compact space during a single assembly operation, reducing operational complexity while ensuring proper electrical connections.
4Volume of moving object
If the stator is designed with separate non-overlapping bus bar end parts, then the structure is simple, but the radial and axial size increases
Solution Approach 1:
The bus bar end parts are arranged in an overlapping nested configuration in the axial direction, allowing one end part to overlap with another. This nesting reduces the overall axial length required for the bus bar assembly, thereby reducing the stator's axial dimension and overall volume without compromising electrical connection functionality.
Solution Approach 2:
The bus bar connection structure transitions from a radial arrangement to an axial overlapping arrangement. By utilizing the axial dimension for overlapping connections rather than requiring radial space for separate connections, the design reduces the radial size of the stator while maintaining all necessary electrical connections.
Data Source
AI summary
Embodiments of the present application provide a stator, comprising a coil group is provided with a first end part, a second end part, multiple coils respectively wound on a multiple teeth, and a transition line part configured to connect multiple coils, the first end part is provided with a first overlapping part having the same position as at least a part of the second end part in the circumferential direction, the second end part is provided with a second overlapping part having the same position as the first overlapping part in the circumferential direction, and a coil connecting part is connected with the first overlapping part and the second overlapping part.