Stator Plate Conductor Joining for Electric Rotary Machines
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Solution Overview
Problem
Conventional stators for electric rotary machines face challenges in achieving sufficient positional accuracy and joining strength due to crimping methods, which also increase production costs and complexity.
Innovation Solution
The stator design incorporates plate conductor slot coils and connection coils with abutment surfaces, reduced thickness step portions, and axial extending portions, allowing for surface contact and joining without the need for precise crimping, using common sheet materials and eliminating the need for additional connecting members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If crimping method is used to join slot coils and connection coils, then joining strength can be obtained, but positional accuracy of projecting portions and hole portions becomes difficult to satisfy and joining strength varies
Solution Approach 1:
The coil is divided into slot coils and connection coils that are joined through crimping. The slot coil and connection coil are segmented components that are assembled together, allowing for modular manufacturing and assembly while maintaining joining strength through the crimping process.
Solution Approach 2:
Instead of requiring high positional accuracy in the projecting portions and hole portions for crimping alignment, the invention inverts the approach by using a crimping structure that accommodates variations in positional accuracy. The crimping portion is designed to provide sufficient joining strength even when positional accuracy is not precisely maintained, thereby solving the contradiction between joining strength and manufacturing precision requirements.
2Strength
If positional accuracy of crimping portions is enhanced to required level, then joining strength can be ensured, but working cost increases and production cost increases
Solution Approach 1:
The invention inverts the conventional approach by not requiring high positional accuracy in crimping portions. Instead of investing in expensive precision manufacturing processes, the crimping structure is designed to achieve sufficient joining strength with standard manufacturing tolerances, thereby reducing working cost and production cost while maintaining adequate joining strength.
Solution Approach 2:
The invention changes the parameters of the crimping structure, specifically the dimensions and configuration of the crimping portions, to optimize the balance between joining strength and manufacturing cost. By adjusting the crimping depth, width, and shape parameters, the design achieves adequate joining strength without requiring excessive positional accuracy, thus controlling production costs.
3Strength
If crimping portions are designed with high positional accuracy, then joining strength is sufficient, but device complexity and production complexity increase
Solution Approach 1:
The invention simplifies the production process by inverting the requirement for high positional accuracy in crimping portions. The crimping structure is designed to function effectively with standard manufacturing tolerances, reducing the complexity of production processes, tooling requirements, and quality control procedures while maintaining sufficient joining strength.
Data Source
AI summary
A stator for an electric rotary machine including a stator core and a coil, wherein the coil has plural slot coils, each slot coil being inserted into the slot, and plural connection coils, each connection coil connecting the slot coils in a position lying further axially outwards than an axial end face of the stator core, and is constituted in such a way that the slot coil and the connection coil are joined at an abutment portion; the slot coil and the connection coil are formed by plate conductors, the plate conductor having a plate surface that is planar and that intersects a thickness direction thereof; and the plate surface of the slot coil is brought into surface contact with the plate surface of the connection coil in the abutment portion.