Stator Coil Springback Prevention via Plastic Deformation
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Solution Overview
Problem
Conventional methods for manufacturing stators for electric rotating machines face challenges in maintaining accurate alignment and cylindrical shape due to springback of electric wires during the rolling process, leading to misalignment and difficulties in assembly.
Innovation Solution
The method involves forming planar electric wires with specific bulges and shoulder parts, rolling them into a spiral or circular-arc shape through plastic deformation to prevent springback, and then assembling them into a hollow cylindrical stator coil, ensuring accurate axial movement and alignment with the stator core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If elastic deformation is used during the rolling step to form the stator coil, then the electric wires can be easily deformed into shape, but springback occurs causing misalignment of in-slot portions and loss of dimensional accuracy
Solution Approach 1:
The patent changes the deformation parameter from elastic to plastic deformation during the rolling step. This allows the electric wires to be permanently formed into the required spiral or circular-arc shape without springback, thereby maintaining alignment accuracy of the in-slot portions while still enabling easy formation of the stator coil structure
Solution Approach 2:
The patent performs preliminary plastic deformation of the electric wires into spiral or circular-arc shapes before final assembly. This preliminary shaping ensures that the wires maintain their formed geometry without springback during subsequent handling and assembly operations, preventing misalignment of in-slot portions
2Manufacturing precision
If plastic deformation is used to roll the electric wires into spiral or circular-arc shapes, then springback is prevented and alignment accuracy is maintained, but the manufacturing process becomes more complex
Solution Approach 1:
The patent replaces complex mechanical alignment and adjustment systems with a straightforward plastic deformation rolling process. By forming the wires into spiral or circular-arc shapes through rolling, the need for complex post-formation alignment mechanisms is eliminated, actually simplifying the overall manufacturing system while maintaining high precision
3Shape
If the in-slot portions are not properly aligned, then the hollow cylindrical shape of the stator coil cannot be maintained, but achieving precise alignment increases assembly difficulty
Solution Approach 1:
The patent changes the deformation mode to plastic deformation, which permanently sets the shape of the electric wires. This ensures that the in-slot portions remain properly aligned throughout assembly operations, maintaining the hollow cylindrical shape of the stator coil while requiring no complex alignment adjustments during assembly
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 enhances the productivity and reliability of stator assembly by preventing misalignment, improving dimensional accuracy, and allowing for the use of smaller-scale machinery, resulting in a more cost-effective stator manufacturing process.
Implementation Method 1
rolling each of the planar electric wires through plastic deformation into a spiral or circular-arc shape
Data Source
AI summary
Disclosed is a method of manufacturing a stator for an electric rotating machine. The method includes the steps of: (1) forming a plurality of planar electric wires, each of the planar electric wires including a plurality of in-slot portions to be received in slots of a stator core and a plurality of turn portions to be located outside of the slots to connect the in-slot portions; (2) rolling each of the planar electric wires through plastic deformation into a spiral or circular-arc shape; (3) forming a hollow cylindrical stator coil by assembling the rolled electric wires through operations of making relative axial movement therebetween; and (4) assembling the stator core and the stator coil together to form the stator.