Stator Coil Layout for Radial Access to Intermediate Protrusions
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Solution Overview
Problem
The existing stator design with segment coils, as described in JP 6742263 A, faces difficulties in performing work on protrusions between the radially outermost and innermost protrusions due to their long lengths, making it challenging to connect terminal coils or irradiate them with laser light from both radial directions.
Innovation Solution
A stator design featuring a stator core with slots containing linear coil portions that have shorter protrusions at the outermost and innermost positions, allowing for easier access and connection from both radial sides, with busbar members connecting the intermediate coil portions, facilitating work such as bringing busbars close or irradiating with laser light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the protruding lengths of the radially outermost and innermost protrusions are made long, then the connection between segment coils is improved, but the accessibility for work on intermediate protrusions from radial directions deteriorates
Solution Approach 1:
The patent applies local quality by differentiating the protruding lengths of different coil portions. Specifically, the outermost and innermost coil portions have shorter protruding lengths, while intermediate coil portions have longer protruding lengths. This localized differentiation allows intermediate protrusions to be accessible from radial directions for work operations, while maintaining sufficient connection reliability through the longer protrusions of intermediate portions.
2Stability of the object's composition
If the protruding lengths of outermost and innermost protrusions are made long, then the structural stability is improved, but the ease of performing work such as bringing terminal coils close or irradiating with laser light deteriorates
Solution Approach 1:
The patent implements local quality by assigning different protruding lengths to different radial positions. The outermost and innermost coil portions have shorter protruding lengths to facilitate work operations such as bringing terminal coils close or irradiating with laser light from radial directions. Meanwhile, intermediate coil portions have longer protruding lengths to maintain structural stability and ensure reliable connections.
3Manufacturing precision
If the protruding lengths of all coil portions are made uniform and long, then the electrical resistance uniformity is improved, but the accessibility for work on intermediate protrusions from both radial sides deteriorates
Solution Approach 1:
The patent applies local quality by creating a non-uniform protrusion length distribution across different radial positions. Intermediate coil portions have longer protruding lengths that extend beyond the outermost and innermost portions, creating exposed portions that are accessible from both radial sides for work operations. The electrical resistance uniformity is maintained through proper design of the coil windings and connections, while the differentiated protrusion lengths enable manufacturing work from radial directions.
Data Source
AI summary
In this stator, in each of a plurality of slots, a protruding length, in an axial direction, of each of protrusions of an outermost coil portion that is a linear coil portion on a radially outermost side and of an innermost coil portion that is a linear coil portion on a radially innermost side is shorter than a protruding length, in the axial direction, of protrusions of intermediate coil portions that are linear coil portions disposed between the outermost coil portion and the innermost coil portion.