Stator Coil Plastic Deformation Assembly
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Solution Overview
Problem
The existing methods for manufacturing stator coils face challenges such as radial misalignment due to springback of electric wires during rolling, damage to insulating coats from friction, and the need for large-scale machinery, which complicates assembly and increases costs.
Innovation Solution
A method involving the formation of substantially planar electric wires with in-slot and turn portions, rolling them into a spiral shape through plastic deformation to prevent springback, and assembling them using radially and circumferentially positioned components to ensure accurate alignment and prevent interference, allowing for easier handling and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electric wires are rolled into a hollow cylindrical shape by elastic deformation, then the stator coil can be formed, but radial misalignment occurs due to springback making assembly difficult
Solution Approach 1:
The patent changes the deformation parameter from elastic to plastic deformation. By plastically deforming the turn portions into an arc shape during rolling, the electric wires maintain their deformed state without springback, ensuring radial alignment of in-slot portions during assembly while still forming the hollow cylindrical stator coil structure
Solution Approach 2:
The patent divides the electric wire into distinct functional segments: in-slot portions that remain substantially planar and turn portions that are plastically deformed into arc shapes. This segmentation allows different parts of the wire to have different deformation characteristics, with turn portions providing the necessary flexibility for rolling while in-slot portions maintain alignment precision
2Quantity of substance
If electric wires are densely arranged to increase space factor, then slot utilization improves, but insulating coats are damaged due to friction during rolling
Solution Approach 1:
The patent changes the deformation mode from elastic to plastic deformation, which allows the turn portions to be permanently shaped into arc forms. This reduces the need for repeated adjustments and dense packing during assembly, thereby reducing friction between adjacent in-slot portions and protecting their insulating coats while still achieving high space factor
Solution Approach 2:
The patent performs preliminary plastic deformation of the turn portions into arc shapes before assembly. This preliminary shaping ensures that the electric wires maintain their intended configuration during assembly, reducing relative movement and friction between densely packed in-slot portions, thus protecting insulating coats while achieving high space utilization
3Shape
If long electric wires are used to form the stator coil, then the hollow cylindrical shape can be achieved, but handling and assembly become difficult requiring large-scale machinery
Solution Approach 1:
The patent segments the electric wire into in-slot portions and turn portions with distinct functions. The in-slot portions remain substantially planar for easy handling and precise alignment, while the turn portions are plastically deformed into compact arc shapes. This segmentation allows the wire to form the hollow cylindrical shape without requiring excessively long continuous wires, improving handling ease and reducing machinery scale requirements
Solution Approach 2:
The patent changes the deformation state of different wire portions: in-slot portions remain in their original planar state for easy handling, while turn portions are plastically deformed into arc shapes. This differential parameter approach allows the formation of the hollow cylindrical shape using wires of manageable length, eliminating the need for large-scale shaping machinery
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 method ensures reliable radial alignment of stator coils, reduces the risk of insulating coat damage, and enables the use of smaller machinery, enhancing productivity and reducing costs while maintaining the hollow cylindrical shape and ensuring accurate assembly.
Implementation Method 1
rolling each of the planar electric wires by a predetermined number of turns into a spiral shape by plastically deforming each of the turn portions of the electric wire into an arc shape
Implementation Method 2
axially moving first and second components relative to each other with both the first and second components radially elastically deformed
Data Source
AI summary
A method of manufacturing a stator coil includes the steps of: (1) forming substantially planar electric wires each including in-slot portions to be received in slots of a stator core and turn portions to be located outside of the slots to connect the in-slot portions; (2) rolling each of the planar electric wires into a spiral shape by plastically deforming the turn portions; and (3) assembling the rolled electric wires through relative axial movements therebetween, each of the relative axial movements being made by axially moving first and second components relative to each other with both the first and second components radially elastically deformed and with each of the first and second components circumferentially positioned by at least one positioning member, each of the first and second components being one of the rolled electric wires or an electric wire sub-assembly comprised of a plurality of the rolled electric wires.