Rotary Electric Machine Stator Coils Pressure Molding
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Solution Overview
Problem
The manufacturing process of rotary electric machines is hindered by the lengthy molding process for stator coils, which limits process time and complicates recycling, particularly in separating iron and copper members.
Innovation Solution
The stator coils are integrally molded in advance using pressure molding and round copper wire, allowing for assembly-focused manufacturing and easy disassembly, with heat conduction enhanced by direct contact with brackets and insulating materials to maintain cooling performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If stator coils are molded by molding resin to fabricate a stator, then cooling performance for stator coils is enhanced, but process time is extended and ease of recycling is reduced
Solution Approach 1:
The stator coils are integrally molded in advance as a pre-fabricated component before assembly into the rotary electric machine. This preliminary manufacturing of the stator coil assembly allows the main production line to skip the time-consuming molding process and proceed directly to assembly operations, thereby reducing overall process time while maintaining the cooling performance benefits of resin-molded coils
Solution Approach 2:
The stator is divided into separate components: integrally molded stator coils and separate stator cores. This segmentation allows the stator coils to be manufactured independently in advance, enabling parallel processing and reducing the sequential process time required when coils and cores are manufactured as a single integrated unit
2Temperature
If stator coils are molded by molding resin to fabricate a stator, then cooling performance for stator coils is enhanced, but ease of recycling is reduced
Solution Approach 1:
The stator is segmented into separately manufactured components: integrally molded stator coils and separate stator cores. This segmentation enables easy disassembly by simply removing fastening bolts, allowing for straightforward separation of iron members (stator cores) and copper members (stator coils) during recycling processes
Solution Approach 2:
The stator coils are extracted as a separate, pre-fabricated component from the overall stator assembly. This extraction allows the coils to be manufactured with optimal resin molding for cooling performance while maintaining independence from the stator cores, facilitating easy separation and recycling of different materials
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 approach significantly reduces manufacturing time, enhances recycling efficiency, and maintains or improves cooling performance, enabling higher rated outputs and resource savings.
Implementation Method 1
heat generated in the stator coils is directly radiated to a bracket from coil ends of the stator coils
Implementation Method 2
each of the air-cored coils being formed by winding a round copper wire and having an outer shape subjected to pressure molding
Data Source
Figure 1
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AI summary
A rotary electric machine according to an embodiment includes a substantially cylindrical rotator (31) that is freely rotatably supported, a stator (30), and brackets (43, 44) which support the rotator (31) and the stator (30). The stator (30) includes stator coils (40) in which a plurality of air-cored coils (46) are arranged in a ring shape and are integrated by resin, each of the air-cored coils (46) being formed by winding a round copper wire and having an outer shape subjected to pressure molding, and stator cores (45) divided for each of teeth.