Motor Stator Coil Lead Layout for Simpler Bus Bar Connection
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Solution Overview
Problem
Existing motor coil configurations require complex and costly assembly processes due to uneven lead part positions, leading to increased assembly costs and complexity in connecting coils and bus bars.
Innovation Solution
A coil design with a winding part featuring first and second lead parts that are bent and positioned to be equidistant from the center of the motor, allowing for standardized and simplified connections between coils and bus bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional coil configuration with uneven lead part positions is used, then the coil can be manufactured with standard winding processes, but the connecting work becomes complicated and requires frequent movement of jigs and connection equipment
Solution Approach 1:
The lead parts are pre-positioned at equal heights and equidistant from the n-th turn during coil manufacturing. This preliminary arrangement of connection points eliminates the need for frequent jig repositioning during assembly, as all connections can be made from a standardized position.
Solution Approach 2:
The lead parts are designed to be at equal heights from the first coil end surface and equidistant from the n-th turn, creating equivalent connection positions. This equipotential arrangement simplifies the connecting process by providing uniform access points for welding or other connection methods.
2Reliability
If welding method is used for connection, then strong electrical connection is achieved, but the welding head cannot be accurately moved to welding position due to narrow gap between lead parts
Solution Approach 1:
The lead parts are arranged in a configuration that provides adequate spatial separation and access from the welding head direction. By positioning lead parts at equal heights and equidistant locations, the design creates sufficient working space for welding equipment to approach and accurately position itself.
3Ease of operation
If coil or stator is moved to facilitate connection, then connection access is improved, but the equipment size and complexity increase
Solution Approach 1:
By designing lead parts to be at equal heights and equidistant positions, the coil maintains optimal connection accessibility in its fixed position during assembly. This eliminates the need for complex moving equipment to reposition coils or stators, as the standardized lead part configuration provides inherent access for all connection operations.
Data Source
AI summary
Provided is a coil including first and second lead parts, and a winding part. The winding part includes first to n-th turns. The winding part includes first and second coil ends. The first lead part extends from the first turn to the n-th turn along an upper surface of the first coil end. The second lead part extends from the n-th turn. The first and second lead parts include respective ends that are equal in height from the upper surface of the first coil end when viewed from a radial direction, and are equidistant from the n-th turn when viewed from an axial direction.