Stator Unit Coil Segmentation for Terminal Wire Connection
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Solution Overview
Problem
The existing stator manufacturing process with concentric-winding coils faces reduced productivity due to the complexity of connecting terminal wires, particularly as it requires gathering and welding of innermost and outermost terminal wires, which complicates the assembly and reduces efficiency.
Innovation Solution
The stator design incorporates distributed-winding coils with unit coils shifted in the circumferential direction, featuring first and second slot-accommodated portions, terminal wires, and coil end portions, allowing for easier connection and assembly by overlapping unit coils in a coil basket configuration, reducing the need for wire bending and enhancing insulation reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If concentric-winding coils are used with traditional terminal wire connection methods, then the stator can be manufactured, but the productivity is reduced due to the complex process of gathering and welding terminal wires
Solution Approach 1:
The coil is segmented into multiple unit coils arranged in a distributed-winding configuration. Each unit coil has its own terminal wires that can be independently positioned and connected, eliminating the need to gather all terminal wires into a single location for welding. This segmentation allows for simplified connection processes and improved manufacturing productivity.
Solution Approach 2:
The terminal wires are arranged in different spatial positions and orientations within the stator core structure. By utilizing the three-dimensional space available in the stator, terminal wires can be connected at multiple locations rather than requiring all wires to be gathered at one point, thereby reducing connection complexity and improving productivity.
2Ease of manufacture
If distributed-winding coils are used, then the coil assembly process becomes more complex, but the terminal wire connection can be simplified through proper configuration
Solution Approach 1:
The unit coils are pre-assembled with their terminal wires positioned and configured before being installed into the stator core. This preliminary arrangement of terminal wires in the distributed-winding configuration allows for simplified connection processes during final assembly, as the wires are already in their proper positions and orientations for connection.
3Reliability
If terminal wires are gathered and welded in traditional methods, then electrical connection is achieved, but insulation reliability may deteriorate due to increased load and bending
Solution Approach 1:
By segmenting the coil into distributed unit coils with independently positioned terminal wires, the mechanical load and bending stresses on individual terminal wires are reduced. Each terminal wire can be connected in its optimal position without requiring excessive bending or gathering, thereby maintaining insulation reliability and preventing deterioration from mechanical stress.
Data Source
AI summary
A stator in which stator coils are formed by a plurality of unit coils arranged so as to be shifted from each other in the circumferential direction and each having: a first slot-accommodated portion; a second slot-accommodated portion; a first terminal wire extending from the first slot-accommodated portion; a second terminal wire extending from the second slot-accommodated portion and shifted from the first terminal wire by one line of a conductive wire; a terminal-side coil end portion; and first and second anti-terminal-side coil end portions, wherein the first terminal wire and the second terminal wire of the respective different unit coils are joined with each other.