Stator Tool Assembly for Compact Two-Layer Winding Heads
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Solution Overview
Problem
The production of a stator with a two-layer winding faces complexity in positioning conductor ends due to irregular interlacing patterns, leading to suboptimal axial winding head height and increased manufacturing costs.
Innovation Solution
A method involving a tool with ring-shaped receiving areas that align conductor ends in a specific rotational position, allowing for precise interconnection without repositioning, and a twisting process to form a compact winding head with uniform bevel angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conductor ends are pre-bent to achieve irregular interlacing patterns, then the interconnection of conductor ends is enabled, but the axial winding head height increases and tolerances are required
Solution Approach 1:
The tool receives and positions conductor ends in their final interlaced arrangement before the winding process. The receiving areas are arranged in a ring with relative positions corresponding to the desired final positions of conductor ends, enabling them to be interconnected without subsequent repositioning or bending operations.
Solution Approach 2:
A tool with receiving areas arranged in a ring serves as an intermediary device. This tool holds conductor ends in the correct relative positions during the winding process, eliminating the need for pre-bending and subsequent repositioning, thereby reducing axial winding head height while enabling proper interconnection.
2Adaptability or versatility
If irregular interlacing patterns are used to achieve proper coil connections, then electrical connection ends and multiple loops per coil are obtained, but conductor ends must be laboriously positioned and bent
Solution Approach 1:
The tool is designed with receiving areas arranged in a ring pattern that corresponds to the desired irregular interlacing pattern. Conductor ends are positioned in these receiving areas before winding, establishing their final relative positions and eliminating the need for laborious positioning and bending operations during or after the winding process.
3Ease of operation
If conventional tools with multiple components are used for positioning conductor ends, then flexibility in positioning is achieved, but manufacturing cost and device complexity increase
Solution Approach 1:
The invention combines multiple positioning functions into a single tool component. The tool features a ring with multiple receiving areas that can simultaneously position multiple conductor ends in their correct relative positions, eliminating the need for multiple separate positioning devices or complex multi-component tooling systems.
Data Source
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AI summary
The invention relates to a method for producing a stator (1), wherein a tool (28, 28') with receiving areas (30) is in each case provided on a front side (18) of a sheet metal packet (2) for one or both layers (10, 11) of a two-layer winding (12), wherein a relative arrangement of the receiving areas (30) corresponds to a relative end position provided for conductor ends (23) of the conductor elements (6). In a positioning process, the tool (28, 28') is moved to a first rotational position (49) and each conductor end (23) of a first group (48) of the conductor elements (6, 7) is placed in each case in one of the receiving areas (30). The tool (28, 28') is then rotated into at least one further rotational position (50) and each conductor end (23) of a further group (51) of conductor elements (6, 7) is placed in each case in one of the receiving areas (30) until the conductor ends (23) of all the conductor elements (6, 7) of the layer (10, 11) have the relative end position with respect to each other.