Stator Conductor Assembly Continuous Insertion
Solution Overview
Problem
The manufacturing of stators for vehicular electric motors is inefficient due to the high number of welding locations required, which increases time, cost, and effort, and results in potential errors.
Innovation Solution
A stator design where conductors are disposed continuously through multiple slots, reducing the number of welding locations by bending and coupling conductors before insertion, and welding them after placement, thereby minimizing the number of couplings and welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conductors are inserted separately into each slot and coupled together with multiple welds, then the stator assembly can be completed with conventional manufacturing methods, but the number of welding locations increases, resulting in increased manufacturing time, cost, and potential errors
Solution Approach 1:
The conductor is pre-bent into the required configuration before insertion into the stator slots. This preliminary shaping action eliminates the need for multiple welding locations during assembly, as the conductor can be continuously inserted through multiple slots in a single operation, thereby reducing manufacturing time and complexity
Solution Approach 2:
The conductor is divided into multiple segments or sections that are pre-bent to fit specific slot configurations. These segmented portions are then inserted into corresponding slots, allowing for reduced welding locations while maintaining proper conductor placement and electrical connectivity
2Ease of manufacture
If conductors are inserted separately into each slot and coupled together with multiple welds, then the stator assembly can be completed with conventional manufacturing methods, but the number of welding locations increases, resulting in increased cost and effort
Solution Approach 1:
The conductor is pre-bent into the required configuration before insertion into the stator slots. This preliminary shaping action eliminates the need for multiple welding locations during assembly, as the conductor can be continuously inserted through multiple slots in a single operation, thereby reducing manufacturing time and complexity
Solution Approach 2:
Multiple conductor insertion operations that would traditionally require separate welding locations are merged into a single continuous insertion process. The pre-bent conductor design allows one continuous piece of conductor to pass through multiple slots, combining what would have been separate assembly steps into one operation
3Ease of manufacture
If conductors are inserted separately into each slot and coupled together with multiple welds, then the stator assembly can be completed with conventional manufacturing methods, but the number of welding locations increases, resulting in increased coupling errors
Solution Approach 1:
The conductor is pre-bent into the required configuration before insertion into the stator slots. This preliminary shaping action eliminates the need for multiple welding locations during assembly, as the conductor can be continuously inserted through multiple slots in a single operation, thereby reducing manufacturing time and complexity
Solution Approach 2:
The invention converts the potential harm of complex multi-slot conductor placement into a benefit by using pre-bent conductors. The pre-bending process, which would traditionally be a complex manual operation, is transformed into a controlled manufacturing step that actually improves precision and reduces errors during the insertion phase
Data Source
AI summary
A stator includes a stator core, a plurality of slots, and a conductor. The plurality of slots are formed within the stator core. The conductor is disposed continuously within at least two of the plurality of openings.