Stator Coil End Connection Method Preventing Conductor Collisions
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Solution Overview
Problem
The existing manufacturing method for stator coils often results in assembly failures due to end portions of conductor segments hitting each other during the connection process inside the slots of a stator core.
Innovation Solution
The method involves using coupling members to connect the end portions of conductor segments inserted from opposite ends of a stator core, with a press-in and connecting process that guides the segments to avoid collisions and includes a swaged connection to improve joint reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conductor segments are inserted into slots from both ends and pressed in simultaneously, then assembly efficiency is improved, but assembly failure occurs due to collision between end portions
Solution Approach 1:
The patent applies preliminary action by pre-mounting coupling members to either one-side or other-side conductor segments before insertion. This advance preparation allows the pressed-in operation to proceed smoothly without collision, as the coupling member acts as a buffer that prevents direct contact between opposing end portions during the pressing process.
2Reliability
If coupling members are mounted to conductor segments before insertion, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The patent merges the mounting operation and the pressing-in operation into a single integrated process. By mounting coupling members to conductor segments before insertion, the patent combines two separate operations (mounting + pressing) into one continuous action, reducing the total number of steps and simplifying the overall assembly process while ensuring reliable connections.
Data Source
AI summary
Provided is a manufacturing method for a stator coil in which end portions of one-side conductor segments inserted into slots from the side of one end in an axial direction of a stator core and end portions of other-side conductor segments are connected to each other through coupling members inside the slots. The method includes: pressing in the one-side conductor segment or the other-side conductor segment in an insertion direction in a state where the end portion of the one-side conductor segment or the end portion of the other-side conductor segment, or an end portion of the coupling member has been moved toward the inner circumferential side of the stator core; connecting the end portion of the one-side conductor segment and the end portion of the other-side conductor segment to each other; and executing the pressing in and the connecting sequentially from the outer circumferential side of the stator core.