Stator Segment Coil Bending for Welding Accessibility
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Solution Overview
Problem
The existing manufacturing method of stators results in increased axial length due to extended leading ends, which complicates proper contact and bonding, leading to reduced bonding accuracy of segment coils.
Innovation Solution
The method involves tilting and bending the leading ends of segment coils relative to the stator core's shaft center, allowing them to approach each other in a parallel manner for precise welding, using a bending process machine with a clamp and bending member to efficiently manage the coils in a narrow space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the leading ends of segment coils are extended in the axial direction to facilitate welding, then the welding accessibility is improved, but the axial length of the stator increases
Solution Approach 1:
The patent transitions from axial direction welding to radial direction welding by tilting the leading ends of segment coils. Instead of extending leading ends axially to reach welding positions, the coils are tilted so that leading ends extend radially outward, allowing welding to occur in the radial dimension rather than requiring axial extension. This resolves the contradiction by achieving welding accessibility through dimensional reorientation rather than length increase.
Solution Approach 2:
The patent applies preliminary tilting action to segment coils before the welding process. By pre-tilting the leading ends to extend radially outward, the coils are positioned in advance for optimal welding accessibility. This preliminary positioning eliminates the need for axial extension while ensuring welding can be performed accurately at the tilted leading ends.
2Length of stationary object
If the leading ends of segment coils are shortened to reduce axial length, then the stator size is reduced, but the bonding accuracy of segment coils deteriorates
Solution Approach 1:
The patent improves bonding accuracy by changing the welding dimension from axial to radial. By tilting leading ends to extend radially, the welding process occurs in a dimension where precision can be maintained even with shorter axial lengths. The radial extension provides a stable, accessible welding surface that ensures accurate bonding without requiring long axial protrusions.
Solution Approach 2:
The patent changes the geometric parameters of segment coil leading ends by tilting them at specific angles. This parameter change transforms the leading ends from axial extensions to radially extended surfaces, optimizing both the bonding accuracy and the overall axial length. The tilt angle parameter allows precise control over the welding surface orientation, ensuring accurate bonding.
3Manufacturing precision
If segment coils are tilted and bent to improve bonding accuracy, then the welding quality is improved, but the device complexity increases
Solution Approach 1:
The bending process machine is segmented into distinct functional modules: a clamp member for securing coil intersections, separate bending members for controlling leading end positions, and a driving unit for coordinated operation. This segmentation allows each component to perform a specific function, simplifying the overall complex task of tilting and bending multiple segment coils with high precision.
Solution Approach 2:
The patent introduces a clamp member as an intermediary device that secures the intersection of segment coils before bending operations. This intermediary component facilitates the bending process by providing a stable reference point and preventing coil displacement, thereby enabling precise tilting and bending while managing the complexity through a dedicated intermediary mechanism.
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 improves the bonding accuracy of segment coils while significantly shortening the axial length of the stator, enhancing the welding quality and reducing the stator's overall size.
Implementation Method 1
tilting the plurality of legs protruded from the plurality of slots, such that leading ends of two legs adjacent to each other in the radial direction are respectively inclined relative to a shaft center of the stator core
Implementation Method 2
bending the leading end of an inner leg located on an inner side in the radial direction out of the clamped two legs, toward an outer circumferential side of the stator core, and bending the leading end of an outer leg located on an outer side in the radial direction
Implementation Method 3
welding the leading ends that are opposed to each other
Implementation Method 4
The plurality of segment coils are configured to form a plurality of stator coils by electrical bonding of leading ends of corresponding legs
Data Source
AI summary
Manufacture of a stator clamps an intersection of two legs that are protruded from different slots provided in a stator core, that are adjacent to each other in a radial direction, and that intersect with each other without any other leading end located in a circumferential direction between their respective leading ends when being viewed in the radial direction. The manufacture then bends a leading end of an inner leg located on an inner side in the radial direction out of the clamped two legs, toward an outer circumferential side of the stator core, while bending a leading end of an outer leg located on an outer side in the radial direction, toward a shaft center side of the stator core.