Stator Manufacturing with Pre-assembled Lamination Blocks
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Solution Overview
Problem
The existing methods for manufacturing stators in rotating electric machines are time-consuming and costly due to the need for stacking and aligning individual laminations, and handling large modules is cumbersome.
Innovation Solution
The method involves creating pre-assembled lamination blocks with end plates and laminations that are impregnated with resin, allowing for easier and faster assembly by stacking and tightening these blocks, eliminating the need for traditional press plates and fingers, and using key bars or tension bars for alignment and tightening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual laminations are stacked one by one with thick aluminium press plates, then the stator can be manufactured with proper tightening and pretension, but the manufacturing process becomes very time-consuming and costly
Solution Approach 1:
The stator assembly is segmented into modular pre-assembled units, each comprising a subset of laminations grouped together with end plates. This segmentation allows parallel processing of multiple modules simultaneously, dramatically reducing overall manufacturing time while maintaining the required tightening and pretension in each module through standardized pressing operations.
Solution Approach 2:
Lamination blocks are pre-assembled and pre-tightened into modular units before final stator assembly. This preliminary action includes stacking laminations, attaching end plates, and applying initial tightening forces to create self-contained modules that are mechanically stable and ready for rapid final assembly, eliminating the need for time-consuming individual lamination handling during final assembly.
2Productivity
If large modules without end plates are used as in US 6 321 439, then manufacturing time is reduced, but handling becomes troubling due to weight and dimension
Solution Approach 1:
End plates are merged with the lamination blocks to form integrated modular units. The end plates serve multiple functions: they provide structural reinforcement to reduce overall module weight, create convenient handling surfaces, define precise stacking interfaces, and enable direct attachment of tension bars. This merging transforms the previously problematic large modules into manageable, ergonomically sound units that are easy to handle while maintaining rapid assembly capability.
3Manufacturing precision
If traditional thick aluminium press plates are used for tightening, then proper pretension is achieved, but the process requires complex press fingers and tension bars arrangement
Solution Approach 1:
The complex arrangement of press fingers and thick aluminium press plates is extracted and replaced by integrating tightening functionality directly into the end plates. The end plates are designed with built-in features for tension bar attachment and direct contact surfaces for pressing operations, eliminating the need for separate press finger components and simplifying the entire tightening mechanism to a more straightforward process.
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 significantly reduces manufacturing time and improves handling ease, enabling faster and more efficient production of stators while maintaining mechanical and electrical integrity.
Implementation Method 1
The end plate is connected to a plurality of laminations; the laminations can be similar (i.e. they can have the same mechanical and/or thermal and/or electrical and/or geometrical features as the laminations 2 or one or more of the features thereof can differ from the corresponding features of the laminations 2
Data Source
Figure 1~5
Figure 6~10
Figure 11~13
AI summary
The method for manufacturing a stator comprises providing a first pre-assembled lamination block (1) comprising an end plate (5) and a plurality of laminations (9), providing a plurality of laminations (2) to partly define a stator, providing a second pre-assembled lamination block (3) comprising an end plate (5) and a plurality of laminations (9), stacking the first pre-assembled lamination block (1), the laminations (2) and the second pre-assembled lamination block (3) to define a pile (13), tightening the pile (13).