Stator Winding Connection Layout for Continuous Coil Assembly
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Solution Overview
Problem
The production of a one-part rotating field winding for brushless electric motors is complicated and costly due to the need for additional holding devices and insulation-stripping steps during assembly, especially when using a single continuous winding wire.
Innovation Solution
A stator with a punch-stacked laminated core and U-shaped insertion pockets allows for a continuous winding wire to be wound monolithically around stator teeth, using insulation-displacement contacts for secure and solder-free connections, eliminating the need for additional holding devices and insulation-stripping, and enabling a simplified winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a continuous winding wire is used to form all coils of the rotating field winding monolithically, then the manufacturing complexity and cost increase due to the need for additional holding devices and insulation-stripping steps, but the winding process can be completed in one continuous operation
Solution Approach 1:
The insertion pocket is divided into multiple contact slots, each capable of receiving and securing a section of the continuous winding wire. This segmentation allows the winding process to be broken into manageable sections while maintaining continuity, eliminating the need for additional holding devices between sections.
Solution Approach 2:
The insertion pocket acts as an intermediary component that facilitates the transition from continuous winding to secure connection. It provides a structured environment with multiple contact slots that guide and secure the winding wire sections, enabling the winding process to proceed continuously while maintaining proper insulation and electrical connections.
2Ease of manufacture
If insulation-displacement contacts are used for connecting the winding wire to phase connections, then solder-free connections are achieved, but additional insulation-stripping steps are required
Solution Approach 1:
The insertion pocket is pre-configured with multiple contact slots that are ready to receive the winding wire sections. The insulation-displacement contacts are pre-positioned within these slots, so that when the winding wire is inserted, the insulation is automatically displaced and electrical contact is immediately established. This preliminary arrangement eliminates the need for separate insulation-stripping steps.
Solution Approach 2:
The insulation-displacement contact mechanism is designed to automatically perform the insulation-stripping function as the winding wire is inserted into the contact slot. The contact structure itself serves the dual purpose of providing electrical connection and removing insulation, eliminating the need for separate insulation removal operations.
3Device complexity
If multiple contact slots are integrated into a single insertion pocket, then the number of components is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
Multiple contact slots are merged into a single integrated insertion pocket structure. This consolidation reduces the total number of separate components and simplifies the overall assembly process. The contact slots are precisely positioned within the pocket to ensure proper alignment and electrical connection for each phase.
Solution Approach 2:
The insertion pocket is designed as a universal component that can accommodate multiple phases of the rotating field winding within a single structure. Each contact slot within the pocket is configured to receive and secure winding wire sections for different phases, making the insertion pocket a multi-functional element that reduces overall component count while maintaining manufacturing precision.
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 simplifies the assembly and production of the stator by allowing continuous winding without interruptions, reducing production costs and assembly complexity, while ensuring reliable and secure electrical connections.
Implementation Method 1
The winding wire is interconnected to an interconnection device for the rotating field winding, that is to say is contact-connected or electrically conductively connected to phase connections on a stator end side
Data Source
AI summary
A stator of an electrical machine, more particularly an electric motor of a motor vehicle, comprising: a laminated stator core, which has a number of stator teeth and is provided with a rotating field winding, which is arranged on the stator teeth and comprises a plurality of phases, the phases of the rotating field winding being formed from a continuously wound winding wire; and a connecting device having a number of U-shaped sockets corresponding to the number of phases, said sockets being provided for each holding one insulation displacement contact as a point of connection of the winding wire to phase terminals on a stator end face, each socket having two vertical U legs and a contact slot arranged therebetween for receiving the winding wire, one of the two vertical U legs of the socket being longer in an axial direction than the other vertical U leg in each case.