Resilient Stator Liner for Wire Fill and End Cap Removal
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Solution Overview
Problem
Existing stator manufacturing methods face challenges in maximizing wire fill and efficient winding due to limitations in accessing teeth, leading to complex wire paths and increased costs, particularly with the use of end caps that add length and complexity to the motor.
Innovation Solution
The use of resilient liners between stator teeth, which are conformable from a linear shape to a circular shape, allows for improved access and uniform winding, reducing the need for end caps and simplifying wire paths by providing a flexible and insulating solution that supports efficient coil formation and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If end caps are used to guide additional electrical wires, then the wires are properly positioned, but the motor length increases and wire paths become complex and tortuous
Solution Approach 1:
The patent removes the end cap component entirely from the motor assembly. Instead of using end caps to guide wires, the invention integrates wire routing functionality into the stator core structure itself, eliminating the need for separate end cap components and their associated complex wire paths
Solution Approach 2:
The patent combines the wire guidance function previously performed by end caps into the stator core structure. The stator core is designed with integrated features that guide and position the additional electrical wires, merging multiple functions into a single component
2Reliability
If end caps are used to guide additional electrical wires, then the wires are properly positioned, but the wire paths become complex and tortuous
Solution Approach 1:
The patent removes the end cap component entirely from the motor assembly. Instead of using end caps to guide wires, the invention integrates wire routing functionality into the stator core structure itself, eliminating the need for separate end cap components and their associated complex wire paths
Solution Approach 2:
The patent combines the wire guidance function previously performed by end caps into the stator core structure. The stator core is designed with integrated features that guide and position the additional electrical wires, merging multiple functions into a single component
3Stability of the object's composition
If a rigid hollow cylindrical core with internal teeth is used, then the stator structure is stable, but access around the teeth is limited and slot fill cannot be maximized
Solution Approach 1:
The patent employs a flexible stator core that can be deformed during the winding process. The core transitions from a relaxed state during winding (allowing easy access) to a stable operational shape after winding, enabling both ease of operation and structural stability
4Ease of operation
If the stator is formed by rolling laminations into a round shape, then the linear arrays provide improved access, but the end turns require additional connectors and end caps
Solution Approach 1:
The patent removes the end cap component entirely from the motor assembly. Instead of using end caps to guide wires, the invention integrates wire routing functionality into the stator core structure itself, eliminating the need for separate end cap components and their associated complex wire paths
Solution Approach 2:
The patent combines the wire guidance function previously performed by end caps into the stator core structure. The stator core is designed with integrated features that guide and position the additional electrical wires, merging multiple functions into a single component
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 approach enhances wire fill efficiency, reduces labor costs, and improves the appearance and performance of electric machines by allowing for more uniform and closely packed windings, while minimizing the length and complexity of wire paths.
Implementation Method 1
a liner for use for a resilient stator of an electric machine... The stator is conformable from a first generally extending shape with opposed spaced apart ends and to a second generally hollow circular shape
Data Source
AI summary
A liner for use for a resilient stator of an electric machine for positioning between teeth formed in the stator. The stator is conformable from a first generally extending shape with opposed spaced apart ends and to a second generally hollow circular shape. The liner includes a central portion for positioning in a cavity between the adjacent teeth, a first end portion for limiting motion of the liner extending from the central portion and adapted to cooperate with a first end face of the stator, and a second end portion extending from the central portion and cooperating with a second end face of the stator, opposed to the first end face. The first end portion limits motion of the liner. The liner is positioned between adjacent teeth when the stator is in the first shape and remains in the cavity when the stator is in the second shape.