Rotary Stator Deformed Teeth Winding Retention

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Solution Overview

Problem

The existing designs for rotary electric machine stators face issues where the stator winding can come out of the slots, risking damage to the winding and insulation, and previous solutions like crushing the wire or using protrusions can damage the wire or require forceful insertion.

Innovation Solution

The stator body features deformed teeth with protrusions formed by radial material displacement, creating a secure fit for the stator winding without damaging it, using a tooling process that deforms the teeth to extend material into adjacent slots, ensuring the winding is securely held without protrusions initially present.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If protrusions are created by cutting the loose end of teeth to prevent winding from coming out, then the winding is secured in the slots, but the wire and insulation are likely to be damaged during forceful insertion

Engineering Contradiction:

Improvewinding security in slotsVSAvoiddamage to wire and insulation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The protrusions are formed on the teeth before the winding is inserted into the slots. This preliminary formation of protrusions allows the winding to be guided into the slots without forceful insertion, preventing damage to the wire and insulation while ensuring the winding is securely retained.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The protrusions act as an intermediary structure between the teeth and the winding. They provide a mechanical guide and retention feature that facilitates smooth insertion of the winding into the slots while preventing the winding from coming out during operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the wire is crushed radially to increase its orthoradial width to lie against the edges of the slot, then the winding is held in place, but the wire and its insulation are likely to be damaged

Engineering Contradiction:

Improvewinding retentionVSAvoiddamage to wire and insulation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Instead of crushing the wire to achieve retention, the invention uses the protrusions on the teeth to naturally guide and retain the winding. The protrusions convert the potential harm of forceful insertion into a beneficial guiding mechanism that secures the winding without damage.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If force is applied to insert the winding into the slot with protrusions, then the winding is secured, but the structure of the stator winding wire or insulation layer is damaged

Engineering Contradiction:

Improvewinding fixationVSAvoidintegrity of wire and insulation

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The protrusions are pre-formed on the teeth before winding insertion. This preliminary structure provides a mechanical advantage that guides the winding into the slots without requiring forceful insertion, thereby maintaining the integrity of the wire and insulation while achieving secure fixation.

Inventive Principle:

Principle #10Preliminary action

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 design effectively secures the stator winding in place without damaging it, preventing obstruction of the rotor and improving magnetic performance by maintaining the winding's integrity and allowing for proper insertion, while eliminating the need for forceful insertion or damaging protrusions.

Implementation Method 1

The protrusion is obtained by material deformation of said deformed tooth

Methodology Applied

Scientific EffectMaterial deformation: Deformation

Data Source

PatentUS10840749B2Rotary electric machine stator having deformed teeth and a plurality of bosses to secure windings

Publication Date: 2020.11.17 VALEO EQUIP ELECTRIC MOTEUR

AI summary

A rotary electric machine stator (2) includes a stator body (20) and a stator winding (22) supported by the stator body (20), in which the stator body extends around an axis (X) while being delimited by an internal radial surface (3) and an external radial surface (4), said stator bodies having a plurality of teeth (6) formed respectively between two slots (5) arranged in said stator body from the internal radial surface and extending axially to receive at least one stator winding element (22).The stator has at least one deformed tooth (6) which comprises, at its loose end (7) helping to define the internal radial surface, at least one protrusion (10) extending across an adjacent slot, said protrusion (10) being obtained by material deformation of said deformed tooth (6).