Stator Winding Method Using Segmented Divisional Cores
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Solution Overview
Problem
Existing methods for manufacturing stators in inner-rotor type rotating electrical machines face challenges with coil winding due to insufficient space, leading to interference issues and longer connection wires that increase electrical resistance and motor inefficiency.
Innovation Solution
A method involving divisional cores arranged non-adjacent in the circumferential direction during winding, allowing for concentrated coil winding and shorter connection wires, which are then shaped to converge at the stator core's end surface, facilitating smoother winding and reduced wire length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If divisional cores are arranged adjacently in the circumferential direction during winding, then the winding process is simplified, but the space for wire winding is insufficient causing interference from adjacent teeth or coils
Solution Approach 1:
The stator core is divided into multiple divisional cores that are arranged in segments around the winding table. This segmentation allows each divisional core to be positioned independently, creating sufficient space between adjacent divisional cores for wire winding operations without interference from neighboring teeth or coils.
Solution Approach 2:
The divisional cores are arranged in a circumferential pattern around the winding table rather than in a linear sequence. This dimensional arrangement optimizes the spatial distribution, providing adequate clearance for wire winding while maintaining manufacturing efficiency.
2Reliability
If connection wires are made long to connect coils after divisional cores are arranged annularly, then the stator can be assembled, but the electrical resistance increases and motor efficiency decreases
Solution Approach 1:
Connection wires are prepared with predetermined lengths and routing paths before the divisional cores are assembled into the final annular configuration. This preliminary preparation ensures that the connection wires are optimally sized, minimizing electrical resistance while still enabling proper stator assembly.
Solution Approach 2:
The length and routing parameters of connection wires are optimized based on the predetermined arrangement of divisional cores. By calculating the exact required length before assembly, the connection wires are made neither too long (increasing resistance) nor too short (preventing assembly), thus minimizing energy loss.
3Device complexity
If the gap between adjacent divisional cores is determined by film insulator dimensions, then the structure is simplified, but the connection wires become longer increasing stator size and complexity
Solution Approach 1:
The gap between adjacent divisional cores is locally optimized to be just sufficient for the connection wires, rather than being uniformly determined by film insulator dimensions throughout. This local optimization allows connection wires to be shorter while maintaining structural integrity and insulation requirements.
Data Source
AI summary
In a state in which a first divisional core and a second divisional core are arranged in a state spaced from each other and adjacent to each other, a first coil and a second coil are each wound around a tooth. The first coil and the second coil are in the same phase. In a state in which a plurality of divisional cores are arranged annularly so that their teeth are oriented in a radially inward direction, the first divisional core and the second divisional core are not adjacent to each other in the circumferential direction. A plurality of connection wires are shaped to converge at an end surface of a stator core. This facilitates the winding of the coils around the divisional cores. Further, the connection wires can be shortened.