Stator Coil Segmentation for Automated Slot Filling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing rotating electrical machines with double-layer lap winding coils face difficulties in mechanizing the operation of arranging coils in slots due to the need to temporarily remove and reposition coil portions, which complicates automation.
Innovation Solution
The stator coil is structured with specific coil portions arranged in a manner that allows for automated slot filling by initially placing the first coil portion, followed by the third coil portion, and then the second coil portion, enabling the final coil portions to be inserted without bypassing the initial ones, thus simplifying the arrangement process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If double-layer lap winding coils are arranged in all slots with alternating inner/outer side positioning, then flux linkage balance and insulation performance are improved, but the coil arrangement process becomes complex and difficult to automate
Solution Approach 1:
The coil is divided into three distinct portions (first, second, and third coil portions) with different arrangement configurations. The first and second coil portions are arranged on the outer side of slots, while the third coil portion is arranged on the inner side. This segmentation allows each portion to be positioned independently, enabling automated arrangement without requiring temporary removal and repositioning operations.
Solution Approach 2:
The first coil portion is arranged in slots in advance before the second coil portion is arranged. This preliminary arrangement establishes a foundation that allows subsequent automated placement of the second coil portion without interference, eliminating the need for bypass operations and enabling full automation of the coil arrangement process.
2Manufacturing precision
If slot-housed portions are arranged on both inner and outer sides of slots, then manufacturing precision and electrical performance are enhanced, but the arrangement process requires temporary removal and repositioning of coil portions
Solution Approach 1:
The coil is divided into three distinct portions (first, second, and third coil portions) with different arrangement configurations. The first and second coil portions are arranged on the outer side of slots, while the third coil portion is arranged on the inner side. This segmentation allows each portion to be positioned independently, enabling automated arrangement without requiring temporary removal and repositioning operations.
Solution Approach 2:
The first coil portion is arranged in slots in advance before the second coil portion is arranged. This preliminary arrangement establishes a foundation that allows subsequent automated placement of the second coil portion without interference, eliminating the need for bypass operations and enabling full automation of the coil arrangement process.
Data Source
AI summary
A stator coil that includes a first coil portion including a pair of first slot-housed portions respectively arranged on an outer side of a first slot of the stator core in a radial direction and on an outer side of a second slot of the stator core in the radial direction; a second coil portion including a pair of second slot-housed portions respectively arranged on an inner side of the first slot in the radial direction and on an inner side of a third slot in the radial direction, the third slot being arranged across the first slot from the second slot in a circumferential direction; and a third coil portion including a pair of third slot-housed portions respectively arranged on an inner side and on an outer side in the radial direction.