Motor Stator Connection Line Bending for Tool Access
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Solution Overview
Problem
Existing connection methods for stator coils in electric motors are cumbersome due to insufficient space for tooling during plastic deformation, especially when coil ends need to be bent at specific angles, leading to potential interference with surrounding components.
Innovation Solution
A connection line with a first bent portion towards the coil and a second bent portion positioned closer to the coil than the first, allowing for a larger distance between the coil end and the first bent portion to accommodate tooling, and enabling the connection line to be bent at an adjusted angle, thus preventing a large stator size and ensuring space for deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the coil end is bent at a required angle using a conventional tooling method, then the electrical connection is achieved, but sufficient space cannot be ensured for the tool when the distance between the coil main body and bending position is short
Solution Approach 1:
The connection line is divided into multiple segments with different bending portions (first bent portion and second bent portion) at different locations. This segmentation allows the bending operation to be performed in stages, with each bending portion serving a specific function in the overall connection process, thereby enabling tooling operations in limited spaces.
Solution Approach 2:
The connection line utilizes three-dimensional spatial arrangement by creating bent portions that extend in different directions and dimensions. The first bent portion and second bent portion are positioned at different radial distances from the coil main body, allowing tooling access from multiple dimensional perspectives rather than being constrained to a single plane.
2Ease of manufacture
If the connection line is configured to allow tool access for bending, then sufficient space for deformation is ensured, but the stator size may increase
Solution Approach 1:
The connection line has different structural configurations at different locations: the first bent portion is positioned closer to the coil main body with specific bending characteristics, while the second bent portion is positioned farther away with different bending characteristics. This local differentiation allows optimized tooling access at each location without uniformly increasing the entire stator size.
Solution Approach 2:
The connection line configuration allows for dynamic adaptation during the bending process. The dual bent portion structure enables sequential bending operations where the first bent portion can be formed with controlled deformation, followed by the second bent portion, allowing the structure to adapt to tooling requirements during manufacturing without permanent size increase.
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 configuration allows for easier and stronger bonding of the connection line to the terminal member, reducing stator size and facilitating tool access for deformation, while ensuring robust electrical connections and simplified assembly.
Implementation Method 1
a plastically deformable connection line... a first bent portion provided between the radially inner end of the coil and the terminal member and bent toward the coil; and a second bent portion provided between the first bent portion and the terminal member and bent away from the coil
Data Source
AI summary
A connection line has a first bent portion bent toward a coil's main body in a vicinity of a stator core's axial length limit line. Furthermore, the connection line at a portion closer to the coil's main body than the first bent portion has a second bent portion bent away from the coil's main body. Furthermore, the connection line has a third bent portion bent away from the coil's main body to have a connection portion along an end surface of the terminal member in contact therewith generally parallel thereto.