Stator Manufacturing Method Overlapping Coil Mounting and Welding
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Solution Overview
Problem
The existing manufacturing methods for stators require additional devices for coil placement and welding, leading to increased space occupation in factories.
Innovation Solution
A manufacturing method and device that simultaneously mount and weld concentrated winding coils on a stator core, allowing for the integration of coil mounting and welding processes in the same step, reducing the number of devices needed and space occupied.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is carried out after all coils are placed in the stator core, then the welding process can be completed, but an extra device is needed for placing coils and welding, increasing the space occupied in the factory
Solution Approach 1:
The patent combines the coil placement function and welding function into a single integrated device. The device includes a placement unit that positions coils on the stator core and a welding unit that welds coil ends, both operations being performed by the same equipment rather than requiring separate placement devices and welding devices.
Solution Approach 2:
The welding operation is performed preliminarily during the coil placement process rather than waiting until all coils are placed. The control unit coordinates the welding unit to weld coil ends as they are being placed, overlapping the placement and welding operations in time to reduce total manufacturing time and device requirements.
2Reliability
If welding is carried out after all coils are placed in the stator core, then the welding process can be completed, but the space occupied by the extra device in the factory increases
Solution Approach 1:
The patent combines the coil placement function and welding function into a single integrated device. The device includes a placement unit that positions coils on the stator core and a welding unit that welds coil ends, both operations being performed by the same equipment rather than requiring separate placement devices and welding devices.
3Ease of manufacture
If separate devices are used for coil placement and welding, then each function can be performed independently, but the number of devices increases and manufacturing efficiency decreases
Solution Approach 1:
The patent combines the coil placement function and welding function into a single integrated device. The device includes a placement unit that positions coils on the stator core and a welding unit that welds coil ends, both operations being performed by the same equipment rather than requiring separate placement devices and welding devices.
Solution Approach 2:
The welding operation is performed preliminarily during the coil placement process rather than waiting until all coils are placed. The control unit coordinates the welding unit to weld coil ends as they are being placed, overlapping the placement and welding operations in time to reduce total manufacturing time and device requirements.
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 reduces the number of devices required and space used during manufacturing, enabling more efficient production by overlapping the mounting and welding processes of concentrated winding coils.
Implementation Method 1
welding end of the concentrated winding coil to a corresponding end of another concentrated winding coil
Data Source
AI summary
A manufacturing method of a stator for manufacturing a stator by mounting a concentrated winding coil wound with a square wire conductor on each of a plurality of teeth in a stator core and welding end of the concentrated winding coil to corresponding end of another concentrated winding coil, characterized in that a first set of concentrated winding coils and a second set of concentrated winding coils are mounted on the teeth, and the welding of each end in the first set of concentrated winding coils and corresponding end in the second set of concentrated winding coils is started while a third set of concentrated winding coils is mounted on the teeth.