Stator Conductor Bending Sequence to Protect Insulation
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Solution Overview
Problem
Existing methods for producing stators in electrical machines often damage the insulation of conductor elements due to friction between conductor ends when twisted, leading to reduced quality and reliability.
Innovation Solution
A method involving a hollow cylindrical laminated core with receiving grooves, where conductor elements are inserted and bent in a radial direction using inner and outer bending tools, reducing friction and preventing insulation damage during subsequent circumferential bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conductor elements are twisted and positioned in adjacent layers, then the stator can be assembled, but the insulation of conductor elements is damaged due to friction
Solution Approach 1:
The conductor element projections are pre-bent in the radial direction before being positioned in adjacent layers. This preliminary bending creates spacing between the conductor elements, preventing friction and insulation damage during subsequent assembly operations.
Solution Approach 2:
The radial bending of conductor element projections acts as an intermediary measure that creates necessary spacing between conductors. This spacing serves as a buffer that prevents direct contact and friction between adjacent conductor elements during assembly.
2Device complexity
If conductor element projections are bent in the circumferential direction without radial bending, then assembly is simplified, but insulation is scraped off due to friction
Solution Approach 1:
The conductor element projections are first bent in the radial direction to create spacing, and only then are they bent in the circumferential direction. This sequence of preliminary radial bending followed by circumferential bending prevents insulation damage during the final positioning.
Solution Approach 2:
The bending process is divided into two separate stages: first radial bending to create spacing, then circumferential bending for final positioning. This segmentation of the bending operation allows each step to perform its specific function without causing harm to the insulation.
3Volume of moving object
If conductor elements are positioned close together, then space is utilized efficiently, but friction increases causing insulation damage
Solution Approach 1:
The radial bending of conductor element projections is performed in advance to create necessary spacing between conductors. This preliminary spacing prevents friction during assembly while still allowing efficient space utilization in the final stator configuration.
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
The method effectively reduces friction between conductor elements, preserving the insulation layer and improving the quality of the stator by allowing for precise bending without scraping off the insulation, thus enhancing the stator's performance and durability.
Implementation Method 1
the friction between the conductor elements can be reduced during the subsequent bending of the conductor element projections in the circumferential direction
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The invention relates to a method for producing a semi-finished product of a stator (1), wherein the method comprises the following method steps: - providing a laminated core (2), wherein the laminated core (2) has a plurality of receiving grooves (5) distributed in a circumferential direction; - providing a plurality of conductor elements (3, 4); - inserting the conductor elements (3, 4) into at least some of the receiving grooves (5), the conductor elements (3, 4) being inserted into the receiving grooves (5) in such a way that conductor element overhangs (11, 12) of the conductor elements (3, 4) protrude beyond at least one of the axial end faces (7, 8) of the laminated core (2) in the axial direction; - bending the conductor element overhangs (11, 12) in the radial direction (22); and - bending the conductor element overhangs (11, 12) of the conductor elements (3, 4) in the circumferential direction (16, 17).