Stator Coil Insertion Jig for Low-Stress Slot Loading
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Solution Overview
Problem
The existing methods for manufacturing stators with winding coils face issues such as deterioration of insulation performance due to high stress and damage during coil insertion, necessitating frequent replacement of insertion members and larger slot sizes, which compromise motor efficiency.
Innovation Solution
A device comprising a winding jig with protrusions for forming coils and an insertion jig with recessed portions allows the coil to be inserted into the stator core by gravity, minimizing stress and eliminating the need for separate insertion members, thereby enhancing insulation performance and reducing slot sizes.
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 considerable force 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 coil is directly inserted into the stator core slots through optimized slot design with rounded bottom corners and appropriate dimensions, eliminating the intermediary component that caused complexity and maintenance issues
Solution Approach 2:
Rather than protecting the coil with an insertion member, the patent inverts the approach by designing the stator core slots themselves to be coil-friendly through rounded bottom corners and optimized dimensions, making the slot geometry adaptive to the coil insertion process rather than relying on an external protective component
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 applies beforehand cushioning by designing the stator core slots with rounded bottom corners and optimized dimensions before coil insertion. This pre-designed slot geometry cushions the coil during insertion, distributing stress evenly and preventing thin film damage without requiring high insertion force
Solution Approach 2:
The patent changes the geometric parameters of the stator core slots, specifically rounding the bottom corners and optimizing slot dimensions. These parameter changes create a more favorable insertion environment that reduces stress on the coil thin film while maintaining effective coil insertion
3Ease of manufacture
If the sizes and assemblability of the insertion member and outer diameter of the wound coil are taken into consideration in slot design, then the coil can be inserted, but the sizes of the slots 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 around the insertion member's dimensions. The slots are optimized solely for coil insertion with rounded bottom corners and appropriate size, reducing slot dimensions and improving motor performance without compromising ease of manufacture
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
This method reduces stress on the coil during insertion, maintains insulation performance, and minimizes slot sizes, improving overall motor efficiency by eliminating the need for additional insertion members.
Implementation Method 1
a power supply unit configured to make the body revolve around a central shaft of the body
Implementation Method 2
an insertion jig configured to receive the winding coil from the winding jig and to insert the winding coil into a stator core
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.