Stator Guide Member for Alternator Winding Compaction
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Solution Overview
Problem
Existing stator designs for rotating electrical machines face challenges in maximizing winding filling rate and efficiently positioning phase inputs and outputs, as the bulky nature of buns limits wire cross-section and requires cumbersome wire overlap, and existing guide members are not adaptable to varying machine environments.
Innovation Solution
A stator with a circular-shaped guide member that directs wire ends along the bun's circumference, allowing for flexible positioning of phase inputs and outputs, and includes a frustoconical connection for improved cooling air flow, made from materials like plastic or copper, with notches and a stepped face to accommodate varying wire thickness and orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the cross-section of the wires is increased to increase the filling rate of the stator, then the filling rate is improved, but the buns become excessively bulky and cannot be properly shaped or compacted
Solution Approach 1:
The guide member is divided into multiple notches that segment the wire paths, allowing individual control of each wire or group of wires. This segmentation enables proper shaping and compaction of buns even with increased wire cross-sections, as each segmented path can be independently managed during the forming process.
Solution Approach 2:
The guide member acts as an intermediary component between the wire insertion process and the final bun formation. By providing a structured path through the notches, it mediates the transition from loose wire insertion to compacted bun formation, enabling both high filling rates and proper shaping.
2Adaptability or versatility
If phase inputs and outputs are positioned at predetermined locations to adapt to machine environment, then adaptability is improved, but wire routing complexity increases
Solution Approach 1:
The guide member is designed with multiple notches that can accommodate different wire routing configurations. The same guide member structure serves multiple functions: guiding wires to different phase input/output locations, managing bun formation, and adapting to various machine environments, thereby reducing overall system complexity.
Solution Approach 2:
The guide member design allows for dynamic adaptation to different positioning requirements. By configuring the notches in specific patterns, the wire routing can be dynamically adjusted to match different machine environments and phase arrangement requirements without changing the fundamental guide member structure.
3Manufacturing precision
If guide members are added to direct wire ends to desired locations, then positioning precision is improved, but device complexity increases
Solution Approach 1:
The guide member combines multiple functions into a single component: wire guidance, bun shaping, and phase input/output positioning. By merging these functions into one integrated part rather than using separate components for each function, the positioning precision is achieved without proportionally increasing device complexity.
Solution Approach 2:
The guide member serves multiple purposes simultaneously: it guides wire ends to precise locations, shapes the buns during compaction, and accommodates different phase configurations. This multi-functionality achieves high positioning precision while minimizing the increase in overall device complexity.
Data Source
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AI summary
The stator has a stator body (17) comprising notches (19), and a winding (18) having coils (65) inserted into the notches and defining winding phases. The coils form chignons (30, 31) on both sides of the body, where each chignon represents an annular top. The winding has an electric input and an output associated to one of the phases. A guiding body (70) made of plastic material is placed on one of the chignons to guide one of the coils. The guiding body is arranged to maintain an end portion (66) of the coil, where the end portion forms one of the input and output. An independent claim is also included for a method for fabricating a stator of an electric rotating machine of an alternator.