Stator with Continuous Winding for Wire Entanglement Reduction
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Solution Overview
Problem
The existing stator designs for inner rotor type motors with split cores face challenges in wire connectivity, leading to entanglement issues and increased manufacturing complexity due to long connecting wires between coils of different phases.
Innovation Solution
The stator design features coils of different phases wound continuously around adjacent tooth portions, with connecting wires forming a ring configuration to minimize length and prevent entanglement, and these wires are connected to create neutral points using arcuate connecting members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If coils of the same phase are arranged in the circumferential direction with a coil of another phase in between, then the number of lead wires can be reduced, but the connecting wires become relatively long and are likely to get entangled
Solution Approach 1:
The patent divides the stator core into multiple independent tooth portions that can be processed separately. Each tooth portion has its own coil winding structure, allowing the lead wire to be continuously wound about adjacent pairs of tooth portions. This segmentation enables the connecting wires to be short and prevents entanglement during the circularization process, while still achieving the reduced number of lead wires through the continuous winding structure.
2Quantity of substance
If the stator is made annular from a spread flat state after coils are wound, then the space factor of coils is increased, but the connecting wires need to be set relatively long with sufficient margin
Solution Approach 1:
The patent performs the coil winding operation while the stator core is in the spread flat state, before the circularization process. The lead wire is continuously wound about adjacent pairs of tooth portions in this flat configuration, creating short connecting wires between coils of different phases. After winding is complete, the stator is then circularized to its annular form. This preliminary winding action ensures that connecting wires remain short even after circularization, preventing entanglement while maintaining high coil space factor.
3Reliability
If both ends of every coil need to be connected to a predetermined conductive member, then the wire connecting procedure becomes complicated
Solution Approach 1:
The patent merges the connection of multiple coils into a single continuous winding operation. The lead wire is continuously wound about adjacent pairs of tooth portions, forming coils of different phases in sequence without requiring separate connection operations for each coil. This continuous winding process automatically creates the necessary electrical connections between coils, eliminating the need for complex separate connection procedures while maintaining reliable electrical connections through the continuous wire structure.
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 reduces wire length, prevents entanglement during manufacturing, and simplifies the production process while maintaining reliable electrical connections, thereby reducing costs and improving insulation reliability.
Implementation Method 1
A lead wire is continuously wound about an adjacent pair of the tooth portions such that coils of different phases are formed in the circumferentially adjacent tooth portions
Data Source
AI summary
A stator having a stator core and coils is disclosed. The stator core includes split core pieces each having a tooth portion. The split core pieces are arranged annularly such that the distal ends of the tooth portions face radially inward. A lead wire is continuously wound about an adjacent pair of the tooth portions such that coils of different phases are formed in the circumferentially adjacent tooth portions, so that a plurality of connecting wires are provided, each connecting wire connecting coils of different phases. The connecting wires are connected to one another while being connected to one another, such that a neutral point is created.