Segment-Conductor Stator Core Assembly Without Radial Pressing Tools
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Solution Overview
Problem
The existing manufacturing process of stators requires tools and members to press the ends of segment conductors together in a radial direction, making the connection process complex and potentially inefficient.
Innovation Solution
A stator design with a cylindrical stator core and a coil configuration where segment conductors are inserted into slots from opposite ends, with an intermediate portion that rotates to create a protrusion, allowing the conductors to be easily connected by being held between the protrusion and side surfaces, eliminating the need for external pressing tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ends of segment conductors are connected by stacking and pressing in the radial direction, then the connection is achieved, but specialized pressing tools and members are required, increasing device complexity
Solution Approach 1:
The stator core itself performs the pressing function through its protrusion that engages with the slot to apply radial force to the segment conductor ends, eliminating the need for external pressing tools. The stator core serves dual purposes: structural support and connection facilitation.
Solution Approach 2:
A protrusion structure is introduced as an intermediary element between the stator core and the segment conductors. This protrusion fits into the slot and provides the necessary pressing force to connect the conductor ends without requiring complex external pressing equipment.
2Reliability
If segment conductors are inserted from opposite ends and connected by external pressing tools, then the connection is achieved, but the manufacturing process becomes more time-consuming and less efficient
Solution Approach 1:
The stator core's protrusion automatically performs the pressing operation during assembly, eliminating the need for separate pressing steps and external tools. This integrates the connection process into the basic assembly workflow, significantly improving manufacturing efficiency.
Solution Approach 2:
The insertion and connection operations are merged into a single integrated process. The protrusion structure allows segment conductors to be inserted from opposite ends and connected simultaneously through the self-pressing action, combining multiple steps into one efficient operation.
3Reliability
If segment conductors are connected by stacking in the radial direction, then electrical connection is achieved, but the process requires specialized pressing members, increasing manufacturing complexity
Solution Approach 1:
The stator core's protrusion structure provides the pressing force automatically during assembly, eliminating the need for specialized pressing members. This makes the manufacturing process simpler and more accessible while maintaining reliable electrical connections.
Solution Approach 2:
The protrusion acts as an intermediary that simplifies the manufacturing process by providing a built-in pressing mechanism. This intermediary structure eliminates the need for complex external pressing equipment while ensuring reliable conductor connections.
Data Source
AI summary
A stator may include a stator core and a coil. The stator core may include: a first portion; a second portion; and a first intermediate portion interposed between the first portion and the second portion in the axial direction. A first segment conductor and a second segment conductor may overly each other in a circumferential direction of the stator core hr a slot within an area of the first intermediate portion. A first side surface may include a first protrusion provided by the first intermediate portion protruding with respect to the first portion and the second portion. The first segment conductor and the second segment conductor may be held between the first protrusion and a second side surface such that the first, segment conductor and the second segment conductor are connected with each other.