Internal Rotor Stator Using Flyer Winding and Modular Switching Disk
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Solution Overview
Problem
Existing stators for internal rotor electric motors require high production costs and are prone to leakage currents due to complex wiring and assembly processes, with individual winding connections being time-consuming and difficult to isolate electrically.
Innovation Solution
The motor windings are wound using flyer technology, with opposite windings directly connected and an insulating body featuring locking pieces and contact tongues, allowing for a modular design with a separate pre-connected switching disk, reducing production complexity and leakage current issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual winding connections are made manually for each stator, then electrical isolation and control of windings is achieved, but production time and costs increase significantly
Solution Approach 1:
The stator is divided into modular components: the stator core with pole teeth, the insulating body with integrated locking pieces, and a separate switching disc. This segmentation allows parallel production of components and simplifies assembly, reducing production time while maintaining electrical isolation through the insulating body's design.
Solution Approach 2:
The insulating body with locking pieces is prepared in advance and integrated into the stator core before winding assembly. The switching disc is pre-assembled with electrical connections. These preliminary preparations enable rapid final assembly without time-consuming on-site wiring, significantly reducing production time while ensuring proper electrical isolation.
2Adaptability or versatility
If complex wiring is used to connect all windings to control circuits, then winding control is achieved, but the amount of wiring and assembly complexity increases
Solution Approach 1:
The switching disc acts as an intermediary component between the motor windings and the control circuit. It integrates multiple electrical connections and switching functions in a single modular unit, reducing the complexity of wiring while maintaining full control capability over the windings.
Solution Approach 2:
The switching disc performs multiple functions: it provides electrical connections for all windings, implements switching control, and serves as a mounting structure for control circuitry. This multi-functionality reduces the overall device complexity by consolidating multiple components into one universal element.
3Reliability
If windings are connected after the yoke ring is pressed on, then electrical protective paths are established, but production efficiency decreases
Solution Approach 1:
The insulating body with integrated locking pieces is installed on the stator core before the yoke ring is pressed on. This preliminary action allows electrical connections to be prepared in advance, and the yoke ring can be installed subsequently without disrupting the wiring process, thereby maintaining both electrical protection and production efficiency.
4Reliability
If a integrated design with all connections made on the stator is used, then electrical isolation is ensured, but production flexibility and rationalization are reduced
Solution Approach 1:
The design is segmented into the stator core with insulating body and a separate switching disc. This segmentation maintains electrical isolation through the insulating body while allowing the switching disc to be produced, tested, and assembled separately, thereby enhancing production flexibility and rationalization.
Data Source
Figure 1
Figure 2~5
Figure 3~4
AI summary
The present invention relates to a stator for an electric motor designed as an internal rotor. The stator comprises a laminated stator core comprising individual laminated sheet metal cuttings, said core having an inner receiving opening (8) for a rotor in an inner stator core (2) having pole teeth (5) which project radially outward in a star shape and which comprise pole tooth webs (7) and end pole-tooth fitting pieces (9). The inner stator core (2) comprises an insulating body (10) which surrounds the pole teeth (5) in such a way that the insulating body forms an electrically insulating coil carrier for motor windings (11) wound about the pole tooth webs (7). The stator further comprises a return ring (3) which surrounds the inner stator packet (2) and which comprises a number of joining grooves (24) corresponding to the number of pole teeth (5), the pole teeth (5) being connected through the pole-tooth fitting pieces (9) thereof to the return ring (3) by way of said joining grooves, and additional grooves (26) formed between the joining grooves (24), wherein the motor windings (11) can be connected to electrical connecting lines (41) through electrical connection contacts. In order to reduce the manufacturing costs of such a stator in a leakage current-proof embodiment, it is proposed to wind the motor windings (11) using a flyer technique, wherein the opposite windings (11) are connected directly to each other and plug contacts (36) sticking out axially are fastened at an end face on the insulating body (10). Said plug contacts are each connected to a free end of the windings (11) led out at the end face, and a switching disk (40) with a number of mating contacts (45) corresponding to the number of the plug contacts (36) to be contacted can be connected to the plug contacts (36) by insertion, wherein the electrical connecting lines (41) are wired in the switching disk (40).