Stator Spacer Geometry for Uniform Coil Segment Welding
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Solution Overview
Problem
In stators with wave-form coil winding, the increased interval between slots in the radial direction leads to varying protruding heights of bent coil segments, causing imbalance during welding, resulting in movement and welding defects due to uneven pressing of bent portions.
Innovation Solution
A stator design incorporating a spacer with a coil support portion that has a support surface positioned differently in the radial direction to uniformly support bent coil segments, ensuring consistent axial height and reducing the imbalance during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the bending angles of the bent portions are kept within a predetermined range to reduce the number of molds, then the manufacturing complexity is reduced, but the protruding heights of the bent portions vary as the outer side in the radial direction is approached, causing imbalance during welding
Solution Approach 1:
The spacer is designed with different radial distances from the end portion of teeth to the support surface at different radial positions. Specifically, the distance on the inner side in the radial direction is made longer than the distance on the outer side, creating local variations in support height that compensate for the varying protruding heights of bent portions at different radial positions
Solution Approach 2:
The invention changes the geometric parameters of the spacer structure by varying the radial distances to different positions. This parameter adjustment allows the support surfaces to be positioned at different axial heights, thereby equalizing the protruding heights of bent portions across different radial positions
2Ease of manufacture
If the protruding heights of bent portions are allowed to vary, then the coil segments can be manufactured more easily, but the bent portions cannot be evenly pressed during welding, causing movement and welding defects
Solution Approach 1:
The spacer is installed on the stator core before the coil segments are assembled and welded. This preliminary action establishes the correct axial positions and equalizes the protruding heights of bent portions in advance, ensuring that subsequent welding operations can be performed uniformly without causing movement or defects
Data Source
AI summary
A stator includes a stator core including a plurality of teeth and a plurality of slots, a coil wound around the plurality of slots, and a spacer disposed on an end portion in an axial direction of the stator core. The coil includes a plurality of coil segments, each including a bent portion and a pair of legs. The spacer includes a coil support portion that is disposed between an end portion of each of the teeth and the bent portion of the coil segment and that has a support surface. A distance from the end portion of each of the teeth to the support surface on an inner side in a radial direction of the stator core is longer than a distance from the end portion of each of the teeth to the support surface on an outer side in the radial direction of the stator core.