Stator Coil Placement With Unfolding Insulation Sheets
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Solution Overview
Problem
The existing stator manufacturing methods face difficulties in providing sufficient mechanical strength to insulating sheets between coils, especially when coils are lap-wound or distributed-wound, leading to challenges in insulation due to increased tensile loads during the placement of slot-housed portions in slots.
Innovation Solution
A stator manufacturing method involving the use of insulating sheets with folded portions that are unfolded to reduce tensile loads by moving slot-housed portions radially outward while placing them in different slots, and a stator manufacturing apparatus with a cutting jig to secure the folded portions, ensuring the insulating sheet's mechanical strength and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the second slot-housed portion is moved radially outward while the interphase insulating paper is placed on the coil end portions, then the distance between slot-housed portions increases and coils can be placed in different slots, but the interphase insulating paper is pulled by the slot-housed portions making it difficult to provide sufficient mechanical strength for insulation
Solution Approach 1:
The insulating paper is preliminarily placed on the coil end portions before the slot-housed portions are moved radially outward. This preliminary placement ensures that the insulating paper is already positioned and secured before the tensile load is applied during the radial movement process, allowing it to maintain sufficient mechanical strength for insulation between coils
Solution Approach 2:
The manufacturing process is segmented into distinct sequential steps: first placing the insulating paper on coil end portions, then moving the second slot-housed portion radially outward. This segmentation allows each operation to be optimized independently, ensuring the insulating paper placement is completed before the radial movement that would otherwise pull and weaken it
2Productivity
If the coils are formed with slot-housed portions placed in slots continuously, then manufacturing steps are simplified, but the interphase insulating paper cannot withstand the tensile load during placement
Solution Approach 1:
The insulating paper is preliminarily placed on the coil end portions before the radial movement and slot placement operations. This preliminary action ensures insulation is established before the coils are subjected to tensile loads during continuous manufacturing, maintaining both productivity and insulation reliability
Solution Approach 2:
The insulating paper acts as a cushioning element placed beforehand between the coils. It is positioned in advance to protect against the tensile loads that will occur during the continuous manufacturing process, ensuring insulation reliability is maintained throughout production
Data Source
AI summary
The stator manufacturing method includes a step involving, simultaneously with or after a first slot-housed portion placing step, moving a second slot-housed portion of each pair of slot-housed portions radially outward while unfolding an insulating sheet in a direction intersecting a direction of extension of folded portions of the insulating sheet, thus placing each second slot-housed portion.