Stator Coil End Volume Reduction via Radial Plate Extension
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Solution Overview
Problem
Conventional stators for rotary electric machines face challenges with low assembly efficiency due to physical connections and large coil end volumes, making downsizing difficult.
Innovation Solution
A stator design featuring a cylindrical stator core with slots, coil segments inserted from one end, and coil end plates connected to the segments on the other end, with leg portions and curved portions to form continuous loops around the rotation axis, reducing the volume of coil end portions and improving assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If coil end portions are extended along the rotation axis direction, then the coil end volume becomes large, but this makes downsizing difficult
Solution Approach 1:
The patent changes the arrangement dimension of coil ends from the rotation axis direction to the radial direction. By extending coil end plates radially from the stator core and arranging coil segments between them, the coil end volume is reduced while maintaining electrical connectivity, directly resolving the contradiction between coil end volume and extension length
2Productivity
If physical connections are used for assembling stator components, then the structure is stable, but assembly efficiency becomes low
Solution Approach 1:
The patent merges the coil segment and coil end plate into an integrated assembly unit. The coil segment is positioned between coil end plates and fixed to them, creating a unified stator coil assembly that reduces the number of separate physical connections needed during assembly, thereby improving assembly efficiency while maintaining structural stability
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
The design enhances assembly efficiency, reduces coil end volume, and achieves uniform electrical resistance, stabilizing current flow and forming a stable rotational magnetic field.
Implementation Method 1
a plurality of coil segments inserted in the slots from one end surface side of the stator core; and a plurality of coil end plates electrically connected with the coil segments on another end surface side of the stator core, wherein the coil segments respectively include: one leg portion received in one of the slots; another leg portion received in one of the slots that is different from the slot for the one leg portion; and a curved portion that is continuously formed between the one leg portion and the other leg portion and is exposed on the one end surface side of the stator core
Data Source
AI summary
A stator for a rotary electric machine includes: a stator core in a cylindrical shape with plural slots formed at an inner circumferential surface; plural coil segments inserted in the slots from one end surface side of the stator core; and plural coil end plates electrically connected with the coil segments on another end surface side of the stator core, wherein the coil segments respectively include: one leg portion; another leg portion; and a curved portion that is continuously formed between the one leg portion and the other leg portion, wherein the coil end plates respectively include: a plate portion in a flat plate shape; and a pair of extended portions, and wherein end portions of the leg portions of the coil segments are connected to the extended portions. It is possible to improve assembility and attain downsizing by reducing the volume of coil end portions for the stator.