Wave-Wound Stator Coil Layout for Consistent Welding Alignment
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Solution Overview
Problem
In stators with wave-form coils, the transition portions of basic and transition coil segments are not aligned properly, leading to welding defects due to variations in the axial direction, which prevents the basic coil segments from being pressed towards the stator core effectively.
Innovation Solution
A stator design where the transition coil segment's second transition portion, with obliquely extending shoulders and rising portions, is positioned to overlap and contact the basic coil segment's first transition portion, allowing the second transition portion to press the first transition portion towards the stator core, ensuring alignment and preventing welding defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the transition portion of the transition coil segment is disposed apart from the transition portions of basic coil segments by an interval in the axial direction, then the transition coil segment can be assembled, but the basic coil segments cannot be reliably pressed toward the stator core, causing welding position variations
Solution Approach 1:
The patent introduces oblique rising portions that extend in both the axial direction and the radial direction, creating a two-dimensional pressing action. This allows the transition portion to press the basic coil segments toward the stator core not only axially but also radially, ensuring reliable contact and consistent welding positions while maintaining assembly feasibility
Solution Approach 2:
The patent changes the geometric parameters of the transition portion by introducing oblique rising portions with specific inclination angles. These parameter changes enable the transition portion to effectively transmit pressing force to the basic coil segments, resolving the contradiction between assembly ease and welding precision
2Manufacturing precision
If the transition portions are overlapping in the axial direction, then pressing force can be transmitted, but the second transition portion must have complex oblique structures increasing manufacturing difficulty
Solution Approach 1:
The transition portion is segmented into distinct functional elements: shoulders extending from the legs, oblique rising portions connecting the shoulders, and tip portions. This segmentation allows each element to perform its specific function while maintaining overall structural clarity, reducing manufacturing complexity despite the overlapping configuration
Solution Approach 2:
The patent employs asymmetric design in the oblique rising portions, where the inclination angles and positions are specifically configured to achieve effective pressing. This asymmetric structure optimizes the pressing force transmission while avoiding unnecessary symmetry that would increase complexity
Data Source
AI summary
A stator includes a stator core and a coil wound around the stator core. The coil includes a basic coil segment including a pair of first legs and a first transition portion disposed on a first end surface side of the stator core, and a transition coil segment including a pair of second legs and a second transition portion. The second transition portion includes a pair of shoulders and a pair of second rising portions. An inclination angle of the second rising portion is larger than an angle of the shoulder with respect to a first end surface, so that the second transition portion is in contact with the first transition portion.