Integrated Stator Housing Casting for Pump Unit Assembly
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Solution Overview
Problem
Existing pump units, particularly heating circulating pumps, require a large number of individual parts and assembly steps due to the separate construction of the stator and stator housing, making mass production inefficient.
Innovation Solution
The stator and stator housing are designed as a one-piece component by casting the iron core into the stator housing, where the windings are applied after casting, reducing the need for separate assembly and providing a permanent fixation, and the stator housing is made of plastic with integrated coil carriers for insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the stator and stator housing are constructed as separate components requiring assembly, then the iron core can be pre-assembled with windings, but the number of individual parts and assembly steps increases
Solution Approach 1:
The patent merges the stator housing and iron core into a single integrated component by casting the iron core directly into the stator housing. This eliminates the need for separate assembly steps and reduces the number of individual parts, directly resolving the contradiction between ease of manufacture and device complexity
2Ease of operation
If the iron core is inserted into the stator housing after winding, then assembly flexibility is improved, but fixation complexity and number of assembly steps increase
Solution Approach 1:
The iron core is cast into the stator housing in advance, before the windings are applied. This preliminary action creates permanent fixation slots that guide and secure the windings during the subsequent winding process, eliminating the need for complex fixation steps after winding while maintaining assembly flexibility
3Productivity
If traditional separate construction is used, then component replacement and repair are easier, but mass production efficiency decreases
Solution Approach 1:
The integrated design of casting the iron core into the stator housing creates a one-piece component that can be manufactured in a single casting operation. This significantly improves mass production efficiency and productivity while the overall manufacturing process remains straightforward and suitable for industrial production
Data Source
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AI summary
The pump assembly has an electric motor, which comprises a stator with an iron core (16) and arranged windings, and which is arranged in a stator housing (6) surrounding the electric motor toward the outside. The stator housing is designed as a cast component, where the iron core is cast. The windings are mounted on the iron core after casting the iron core into the stator housing. An independent claim is also included for a method for producing a pump assembly.