Stator Coil Insertion Jig Geometry for Low-Stress Slot Assembly
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Solution Overview
Problem
Existing methods for manufacturing stators with winding coils face issues such as deterioration of insulation performance due to high stress and damage from insertion members, and increased slot sizes that compromise motor efficiency.
Innovation Solution
A device comprising a winding jig with protrusions for forming coils and an insertion jig with recessed portions allows for the controlled insertion of coils into stator slots without external force, minimizing stress and eliminating the need for separate insertion members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate insertion member is provided between the stator core and the coil during insertion, then the thin film of the coil is protected from direct contact with the stator core, but the insertion member itself is subjected to high stress and needs periodic replacement, and the thin film is still scratched causing insulation deterioration
Solution Approach 1:
The patent removes the separate insertion member from the system entirely. Instead of using an insertion member between the coil and stator core, the invention uses the protrusion on the winding jig to directly control coil insertion, eliminating the intermediary component that caused complexity and maintenance issues
Solution Approach 2:
The protrusion on the winding jig performs the dual function of both guiding the coil during winding and facilitating its insertion into the stator core slots. The coil's own structure (thin film and outer diameter) is utilized to enable insertion without requiring additional protective members
2Productivity
If high stress is applied to insert the coil into the stator core, then the coil is successfully inserted, but the thin film of the coil becomes thinner and insulation performance deteriorates
Solution Approach 1:
The patent changes the geometric parameters of the winding jig by adding a protrusion with specific dimensions (height, width, length) that create optimal clearance with the coil. This geometric modification allows the coil to be inserted with reduced stress by controlling the insertion path and contact points, thereby protecting the thin film while maintaining insertion efficiency
3Ease of manufacture
If the slots of the stator core are designed to accommodate the coil and insertion member, then the coil can be inserted, but the slot sizes are increased and overall motor performance deteriorates
Solution Approach 1:
By removing the insertion member from the system, the patent eliminates the need to design slots that accommodate both the coil and the insertion member. The slots can now be optimized to fit only the coil, reducing slot size and improving motor performance while maintaining ease of assembly through the protrusion-guided insertion method
Data Source
AI summary
Provided is a device for manufacturing a stator, the device including a winding jig configured to wind a coil and to manufacture a winding coil, and an insertion jig configured to receive the winding coil from the winding jig and to insert the winding coil into a stator core, wherein the winding jig comprises a body extending along a longitudinal direction (L1), a power supply unit configured to make the body revolve around a central shaft of the body, and a protrusion formed on a surface of the body.