Stator Winding Contact Layout for Easier Automation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for winding and contacting stators in electric motors are complex, requiring precise alignment and positioning of insulation with carriers, complicating automation and increasing production costs.
Innovation Solution
A method involving a wire guide element that is detachably attached to the insulation, guiding the winding wire to form a loop and allowing separate contact on a carrier, facilitating automation by separating winding and contacting steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If contact elements are mounted on a carrier integrally formed with the stator insulation, then the stator structure is compact, but the winding process requires precise alignment and positioning which complicates automation
Solution Approach 1:
The invention separates the contact elements from the stator insulation by providing them on a separate carrier that can be independently positioned and attached. This segmentation allows the winding process to proceed without requiring precise alignment between the insulation and contact elements, as the carrier can be adjusted independently after winding is complete.
Solution Approach 2:
The winding process is performed first without the contact elements in place, allowing the winding wire to be routed and positioned freely. Only after the winding is complete are the contact elements mounted on the carrier and attached to the stator, eliminating the need for preliminary alignment and positioning during the winding process itself.
2Ease of operation
If the winding wire is routed to individual contact elements in different ways, then each contact element can be individually accessed, but the automation of the winding process is complicated
Solution Approach 1:
The carrier serves multiple functions: it holds all contact elements in a standardized arrangement, provides a common mounting surface that simplifies positioning, and enables automated attachment processes. This universal platform allows all contact elements to be accessed systematically while maintaining automation capability.
Solution Approach 2:
The carrier acts as an intermediary between the stator insulation and the contact elements. It provides a standardized interface that simplifies the routing and connection of winding wires to contact elements, making the process amenable to automation while still allowing individual access to each contact element through the carrier's structured layout.
3Reliability
If the insulation is precisely aligned and positioned with the carrier, then the winding wire can be safely guided over the contact elements, but a high degree of precision is required in automated winding
Solution Approach 1:
By separating the contact elements from the insulation, the invention eliminates the need for precise alignment between these two components. The carrier can be positioned independently after winding is complete, removing the requirement for high-precision alignment during the winding process itself while maintaining reliable wire guidance through the carrier's structured design.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a method for winding and contacting a stator (10) comprising multiple stator teeth (11), each of which is formed by at least one part of a stator core (14) and at least one part of an insulation (12). The method has the following steps: - providing at least one winding wire (20), which has a wire start (21) and a wire end (22), - winding at least one stator tooth (11) with the winding wire (20) in order to form a coil (23), and - contacting the wire start (21) and/or the wire end (22) of the winding wire (20) to a contact support (30) which is separate from the insulation (12). The invention further relates to a stator for an electric motor.