Stator Coil Mold Bending for Motor Model Adaptability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing circumferentially deploying stator coils are complex and difficult to adapt to changes in motor models, particularly in altering the axial and radial lengths of the stator coil.
Innovation Solution
A method involving the use of molds to bend insulating-coating conducting wire into slot-held and coil-end conductor sections, allowing for efficient formation and adjustment of stator coil dimensions without damaging the wire, using a simple manufacturing apparatus that can easily change mold configurations to accommodate different coil shapes and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional methods are used to manufacture circumferentially deploying stator coils, then the manufacturing process can produce stator coils, but the process becomes complicated and difficult to adapt to changes in motor models
Solution Approach 1:
The patent employs movable and adjustable mold pairs that can be repositioned along the conducting wire and adjusted to different positions. This dynamic configuration allows the same manufacturing apparatus to produce stator coils with different axial and radial lengths by simply adjusting the mold positions, rather than requiring different manufacturing lines for different motor models.
Solution Approach 2:
The manufacturing apparatus is designed with universal functionality to handle multiple motor model requirements. The mold pairs can be universally applied to create various coil configurations by adjusting their positions and spacing, making a single apparatus capable of producing coils for different motor types and sizes.
2Adaptability or versatility
If traditional manufacturing methods are used, then stator coils can be produced, but changing the axial and radial lengths of the stator coil becomes difficult
Solution Approach 1:
The mold pairs are designed to be movable along the conducting wire in the axial direction and adjustable in their positioning. This allows the axial length of the stator coil to be easily modified by changing the distance between mold pairs, and the radial length can be adjusted by modifying the mold pair configuration, enabling flexible dimension changes without complex retooling.
3Productivity
If molds are used to bend the conducting wire into coil-end conductor sections, then the stator coil can be formed efficiently, but the conducting wire may be damaged
Solution Approach 1:
The patent carefully controls the bending parameters including the mold pair positioning, pressing force, and bending radius. By optimizing these parameters, the wire is bent into the required coil-end conductor section shapes while minimizing stress concentration and avoiding insulation damage, thus maintaining high formation efficiency without increasing wire damage risk.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the manufacturing process, reduces the risk of wire damage, and enables easy adaptation to various motor models by allowing for adjustable lengths and shapes of stator coils, enhancing the flexibility and efficiency of stator coil production.
Implementation Method 1
bending an insulating-coating conducting wire (i.e., insulated conducting wire) having a longitudinal direction so as to alternately provide the insulating-coating conducting wire with slot-held conductor sections held in slots of the stator and a coil-end conductor section
Data Source
AI summary
A method of manufacturing a stator coil to be wound in and around a stator by bending an insulating-coating conducting wire so as to alternately have slot-held conductor sections to be held in slots of the stator and a coil-end conductor sections each mutually connecting two of the slot-held conductor sections outside the slots. The method includes arranging three or more pairs of molds at predetermined intervals along the insulating-coating conducting wire, each pair of molds having paired molds facing each other with the wire located therebetween. First, the coil-end conductor sections are formed by moving the mold pairs such that the paired molds come closer to each other. Then the slot-held conductor sections are formed by moving the molds, in parallel, in both the longitudinal direction along which the insulating-coating conducting wire extends and in a direction perpendicular to the longitudinal direction.