Stator Core Segmentation for Neutral Point Wiring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for winding and wiring stator cores of three-phase motors are complex and do not adequately simplify the process of forming neutral points, particularly when dealing with annularly-shaped stator cores.
Innovation Solution
A stator structure and manufacturing method where the stator core is formed by coupling twelve core pieces into an annular shape, with windings wound on each piece and lead portions routed from one end to the other, allowing for the formation of a neutral point by connecting the lead portions of the third phase winding through multiple core pieces, simplifying the winding and wiring process by completing the neutral point connection at one end.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the stator core is formed as an annular shape with magnetic polar teeth disposed in an annular shape, then the motor structure is compact and efficient, but the winding and wiring process becomes complicated and time-consuming
Solution Approach 1:
The stator core is divided into multiple individual core pieces (first core piece, second core piece, third core piece, fourth core piece) that can be assembled together to form the annular structure. This segmentation allows windings to be wound on individual pieces separately before assembly, significantly simplifying the winding process compared to working with a complete annular core.
Solution Approach 2:
The windings are wound on the core pieces in advance before the core pieces are assembled into the annular stator core. The neutral wires are also prepared and positioned on the core pieces beforehand. This preliminary action eliminates the need for complex wiring work after the annular structure is formed, reducing both wiring complexity and manufacturing time.
2Device complexity
If neutral wires of coils are connected individually at their respective positions to form a neutral point, then the number of neutral wires is reduced, but the wiring process on annular stator core remains complicated
Solution Approach 1:
The neutral wires are positioned and connected on the individual core pieces before assembly into the annular structure. This preliminary connection eliminates the need for complex wiring work after the annular structure is formed, significantly improving wiring process efficiency while maintaining the simplified neutral point connection approach.
Solution Approach 2:
The neutral wire connections are made on segmented core pieces rather than on the complete annular core. This allows the wiring work to be distributed across multiple simple components rather than concentrated on one complex structure, making the process more manageable and efficient.
3Manufacturing precision
If windings are wound and wired on a complete annular stator core, then the final structure is achieved, but the manufacturing process requires complicated wiring work and significant time
Solution Approach 1:
The stator core is divided into multiple core pieces that can be prepared independently with windings and neutral wire connections. This segmentation allows parallel preparation of multiple components, significantly reducing total manufacturing time while maintaining assembly precision through standardized interfaces between core pieces.
Solution Approach 2:
All winding and wiring operations are completed on the core pieces before final assembly into the annular structure. This preliminary completion of electrical connections eliminates time-consuming wiring work after assembly and ensures manufacturing precision is maintained throughout the process.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A stator core is formed by deforming a core assembly having core pieces coupled in a strip form into an annular shape, and by joining both ends of the core assembly together to make a core-fastening portion. Individual phase windings are routed from one end of the core assembly toward another end. Lead portion (43v) of phase winding (40v) and lead portion (43w) of phase winding (40w) make up respective wire terminals. Lead portion (43u) of another phase winding (40u) is extended through a plural number of the core pieces in a direction of the lead portions (43v and 43w), and a wire terminal of the extended lead portion (43u) and the wire terminals of the other lead portions (43v and 43w) are electrically connected to provide a neutral point of three-phase Y-connection circuit.