Stator Assembly Manufacturing via Radial Winding Insertion
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Solution Overview
Problem
Conventional manufacturing methods for stator assemblies in rotary systems, such as electric motors and generators, are inefficient and labor-intensive, often requiring manual steps that hinder manufacturability and increase costs.
Innovation Solution
A method and system for manufacturing a stator assembly that involves progressively assembling the stator stack using an inner and outer support, with teeth extending radially and windings attached through accessible openings, allowing for automated and efficient construction with high accuracy and repeatability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional manufacturing methods are used for stator assembly, then traditional assembly approaches can be maintained, but manufacturing efficiency is low and manual labor is required
Solution Approach 1:
The stator assembly is divided into modular components: outer support, inner support, teeth, and windings. These segments are manufactured separately and then assembled through the opening, enabling automated handling and assembly while improving manufacturing efficiency
Solution Approach 2:
The inner support acts as an intermediary structure that provides a framework for attaching teeth and windings during manufacturing. This intermediary structure enables automated assembly processes by providing standardized attachment points and geometric constraints
2Strength
If complex assembly structures are used, then structural integrity is maintained, but manufacturing complexity increases
Solution Approach 1:
The inner support is extracted as a separate removable component from the final stator assembly. During manufacturing, it provides structural framework for attaching teeth and windings, but is removed before final assembly, thereby simplifying the manufacturing process while maintaining structural integrity of the final product
3Adaptability or versatility
If multiple parts are used for stator assembly, then structural flexibility is improved, but manufacturing cost increases
Solution Approach 1:
The outer support and inner support are merged in function to provide both structural framework and winding support. The teeth are merged with the supports to form an integrated stator stack, reducing the total number of parts while maintaining structural flexibility through the modular assembly approach
Data Source
AI summary
A method of manufacturing a stator assembly for an electrified rotary system includes attaching a first tooth and a second tooth to an inner support. This includes extending the first tooth and the second tooth radially away from the inner support and includes defining an outer diameter opening between the first tooth and the second tooth. The method also includes attaching a winding about the first tooth including moving a conductive member radially into the outer diameter opening to attach the conductive member to the first tooth. Furthermore, the method includes attaching an outer support to the first tooth and the second tooth including closing off the outer diameter opening with the outer support. Also, the method includes removing the inner support from the first tooth and the second tooth after attaching the outer support.