Three-Phase Stator Segment Wiring for Automated Motor Assembly
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Solution Overview
Problem
Existing three-phase stator assemblies in electric motors require manual connection of coil wires, leading to human error and inefficiencies, with wires often being longer than needed, consuming unnecessary space and material.
Innovation Solution
A three-phase stator assembly design that allows for automated assembly with reduced manual work, featuring stator segments arranged in a ring configuration with connection wires spanning across interposed segments at varying radial distances, optimizing wire length and arrangement for efficient and space-saving connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual connection of coil wires is used, then flexibility in connection is improved, but productivity and manufacturing precision deteriorate due to human error and inefficiency
Solution Approach 1:
The stator assembly is divided into multiple stator segments (n≥2 per set, three sets total) that can be assembled in a ring arrangement. Each segment contains pre-configured coils with connection wires, allowing modular assembly that improves productivity while maintaining connection flexibility through standardized interfaces between segments.
2Ease of operation
If traditional connection wires are used, then ease of connection is improved, but loss of substance deteriorates due to excessive wire length and material consumption
Solution Approach 1:
Connection wires are configured with specific radial distances (first radial distance and second radial distance) optimized for their local position in the ring arrangement. This local optimization ensures wires are neither too long nor too short, minimizing material consumption while maintaining ease of connection at each specific location in the stator assembly.
3Ease of operation
If longer connection wires are used, then ease of assembly is improved, but volume of stationary object deteriorates due to unnecessary space consumption
Solution Approach 1:
The connection wires are designed with specific parameter optimizations including radial distances (first radial distance < second radial distance) and angular positions that minimize wire length while ensuring ease of assembly. The wires span across interposed stator segments at optimized trajectories, reducing unnecessary space consumption in the stator assembly.
4Productivity
If automated assembly is implemented, then productivity is improved, but device complexity deteriorates due to assembly configuration requirements
Solution Approach 1:
Connection wires are pre-configured with specific radial distances and routing paths before assembly. The stator segments are designed with predetermined connection wire arrangements that simplify the automated assembly process, reducing the complexity of real-time configuration while maintaining high productivity through standardized pre-prepared components.
Data Source
AI summary
An electric pump drive motor three-phase stator assembly (1) includes three sets of stator segments (Si,j), configured in a ring about a stator axis (R). Each set includes n≥2 stator segments arranged in an n-fold rotational symmetry about the stator axis. Each stator segment includes a coil (3) having a first coil wire end and a second coil wire end. A plurality of 3n−3 connection wires (Wi,k) connect coils of a respective set of stator segments in series. A first and a second interposed stator segment are arranged in circumferential direction between the two connected coils of the respective set of stator segments. 3n−5 of the connection wires span across the first interposed stator segment at a distance (r1) to the stator axis and across the second interposed stator segment at a second distance (r2) to the stator axis (R). The second distance is larger than the first distance.