Stator Coil Manufacturing via Wave-Shaped Wire Segmentation
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Solution Overview
Problem
Conventional methods for manufacturing stators for electric rotating machines are time-consuming and costly, particularly due to the labor-intensive process of interlacing electric wires, which hinders mass production at low costs.
Innovation Solution
A stator coil configuration featuring electric wires with specific in-slot and turn portions, allowing for the formation of a band-shaped assembly that can be rolled into a hollow cylindrical shape without interlacing, along with a manufacturing method involving wave-shaping, stacking, and rolling of electric wires to reduce manufacturing time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conventional interlacing method is used to form stator coils, then the structural integrity and electrical connectivity are ensured, but the manufacturing time and cost increase significantly
Solution Approach 1:
The electric wires are pre-formed into wave-shaped configurations with predetermined in-slot portions and turn portions before assembly. This preliminary shaping allows the wires to be directly stacked and rolled into the final stator coil structure without requiring time-consuming interlacing operations during manufacturing, thus reducing manufacturing time while maintaining structural integrity
Solution Approach 2:
The stator coil is divided into multiple electric wires, each with distinct functional segments (in-slot portions for electrical connectivity and turn portions for structural formation). These segmented wires are independently formed and then assembled through stacking and rolling, eliminating the need for complex interlacing while preserving both structural integrity and electrical connectivity
2Reliability
If the conventional interlacing method is used to form stator coils, then the structural integrity is maintained, but the manufacturing cost increases
Solution Approach 1:
The wave-shaped electric wires are pre-formed with specific geometries including in-slot portions and turn portions before assembly. This preliminary preparation enables straightforward stacking and rolling operations during manufacturing, significantly reducing labor costs and manufacturing complexity while ensuring the structural integrity of the final stator coil
Solution Approach 2:
The stator coil structure is segmented into multiple independent electric wires with clearly defined functional portions. Each wire is independently formed and then assembled through simple stacking and rolling, eliminating the need for complex interlacing operations and reducing manufacturing costs while maintaining structural integrity
3Reliability
If the conventional interlacing method is used to form stator coils, then the electrical connectivity is ensured, but the productivity decreases
Solution Approach 1:
The electric wires are pre-formed with wave-shaped configurations that include predetermined in-slot portions for electrical connectivity and turn portions for structural formation. This preliminary preparation allows multiple wires to be independently manufactured and then rapidly assembled through stacking and rolling, enabling mass production while ensuring electrical connectivity
Solution Approach 2:
The stator coil is segmented into multiple electric wires with distinct functional portions. The in-slot portions are designed to ensure electrical connectivity, while the turn portions facilitate straightforward assembly. This segmentation allows for independent manufacturing of each wire followed by rapid assembly through stacking and rolling, significantly improving productivity and mass production capability
Data Source
AI summary
A stator includes a stator core and a stator coil comprised of a plurality of electric wires. Each of the electric wires has, at least, first, second, and third in-slot portions and first and second turn portions. The first to third in-slot portions are respectively received in three different slots of the stator core. The first turn portion is located on one axial side of the stator core outside of the slots to connect the first and second in-slot portions. The second turn portion is located on the other axial side of the stator core outside of the slots to connect the second and third in-slot portions. For each of the electric wires, the radial distances of the first to third in-slot portions from the axis of the stator core successively decrease. All of the electric wires are offset from one another in the circumferential direction of the stator core.