Stator Slot Conductor Extrusion Assembly for Precise Motor Winding
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Solution Overview
Problem
Existing methods for manufacturing electric motors with stators and electrical conductors require individual insertion of conductors into stator slots, making the process complex and expensive.
Innovation Solution
The method involves overmolding multiple electrical conductors with an electrical insulator in an extrusion process, allowing them to be handled and fixed together within a stator slot using positioning contours, thereby simplifying assembly and ensuring precise conductor positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual electrical conductors are inserted into stator slots separately, then precise positioning of each conductor is achieved, but the manufacturing process becomes complex and expensive
Solution Approach 1:
Multiple electrical conductors are merged into a single insulating component through co-molding or injection molding processes. The insulator encapsulates several conductors simultaneously, creating an integrated assembly that maintains precise spatial positioning while simplifying the manufacturing process to a single operation rather than multiple individual insertions
Solution Approach 2:
The insulating component is pre-formed with embedded electrical conductors positioned at their final locations before insertion into the stator slot. This preliminary positioning and encapsulation eliminates the need for complex during-assembly positioning operations, as the conductors are already precisely arranged within the insulator
2Productivity
If multiple electrical conductors are handled together as a package, then assembly time is reduced, but precise positioning of individual conductors becomes difficult
Solution Approach 1:
The insulating component serves as a unified structure that combines multiple conductors while maintaining their individual positions. The molding process creates fixed spatial relationships between conductors, ensuring precise positioning is preserved even though they are handled as a single integrated unit
Solution Approach 2:
The insulating material acts as an intermediary that holds conductors in predetermined positions. This intermediary structure provides the necessary positioning function while allowing the conductors to be manipulated together as a package, bridging the gap between simplified handling and precise positioning
3Productivity
If traditional injection molding is used for stator manufacturing, then mass production is enabled, but the process requires multiple separate steps for conductor insertion
Solution Approach 1:
The manufacturing process merges conductor insertion with the stator insulator production in a single co-molding or injection molding operation. This eliminates subsequent separate steps for inserting and positioning individual conductors, reducing the total number of manufacturing steps while maintaining mass production capabilities
Solution Approach 2:
Electrical conductors are preliminarily positioned and encapsulated within the insulating material during the molding process itself, before the stator assembly is completed. This preliminary integration of conductors into the insulator structure eliminates the need for later conductor insertion operations
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 simplifies the assembly of electric motors, reduces manufacturing costs, and allows for precise positioning of electrical conductors within the stator slots, enabling efficient cooling through defined fluid channels.
Implementation Method 1
at least two electrical conductors are encased in an extrusion process with an electrical insulator
Implementation Method 2
a cooling fluid can flow through which... cool the electric motor
Data Source
AI summary
The present invention relates to a method for manufacturing an electric motor having a stator with stator slots and electrical conductors arranged therein. In order to achieve simple production, the following is planned, that at least two electrical conductors are sheathed in an extrusion process with an electrical insulator, which holds the at least two electrical conductors at a distance from one another and has at least one positioning contour, that the at least two electrical conductors together with the electrical insulator are inserted into an associated stator slot and fixed therein via the at least one positioning contour.