Stator Coil Slot Insertion to Prevent Coating Damage
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Solution Overview
Problem
Existing methods for manufacturing coils can cause damage to the coating during the assembly process, particularly when adjacent connecting members and coils come into contact, leading to potential insulation failures.
Innovation Solution
A method involving a two-step process where first coils are connected to connecting members and then inserted into stator core slots, ensuring that the combined insertion amount of adjacent coils is less than the slot length to prevent contact and coating damage, thereby maintaining insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connecting members are arranged in slots of stator core to secure insulation between coils, then insulation between coils is improved, but coating of the coil may be damaged due to contact between connecting members and coils
Solution Approach 1:
The patent applies dimensional change by controlling the axial position (z-direction) of connecting members relative to coil insertion paths. By positioning connecting members at specific axial coordinates that avoid the radial insertion path of coils, the design prevents contact damage while maintaining insulation. This spatial coordinate optimization resolves the contradiction between insulation reliability and coating protection.
2Object-affected harmful factors
If connecting members are positioned to avoid contact with coils, then coating damage is suppressed, but insulation between coils may be compromised
Solution Approach 1:
The patent segments the slot space by introducing insulating plates that divide the slot into multiple regions. These insulating plates are positioned at specific axial locations to provide electrical isolation between adjacent coils without requiring connecting members to contact the coils. This segmentation approach maintains insulation reliability while avoiding coating damage.
Solution Approach 2:
The patent introduces insulating plates as intermediary elements between coils and connecting members. These plates serve as mediators that provide electrical insulation without requiring direct contact between connecting members and coils, thus preventing coating damage while ensuring insulation. The insulating plates act as a buffer that resolves the contradiction between the two requirements.
3Object-affected harmful factors
If connecting members are shifted in axial direction to prevent contact, then coating damage is reduced, but device complexity increases due to precise positioning requirements
Solution Approach 1:
The patent merges the insulation function and positioning function into a single integrated structure. The insulating plates are designed with specific axial positions that simultaneously provide electrical insulation and serve as positioning references for connecting members. This integration simplifies the overall structure by combining multiple functions into one element, reducing the complexity of precise positioning while maintaining coating protection.
Data Source
AI summary
A method of manufacturing a coil includes: a first step of connecting a plurality of first coils to one end of respective a plurality of connecting members; and a second step of inserting the first coils, which are connected to the respective connecting members, and a plurality of second coils into slots of a stator core, so that the second coils are connected to the respective connecting members, which have already been connected to the first coils. Further, in the second step, in a case where insert directions of the two first coils adjacent to each other to be inserted into the slots are different from each other, a sum of insertion amounts of the two first coils adjacent to each other is less than a total length of each of the slots.