Stator Winding Using Continuous Wire to Reduce Complexity
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Solution Overview
Problem
Current methods for winding stators are complex and require multiple components and connections, leading to increased handling difficulties and potential magnetic losses due to short circuits between poles.
Innovation Solution
A method using a continuous thread to wind at least two coil carriers positioned radially on a ring with branches, where the winding is facilitated by a cup holding a stator power connector, allowing for a single-component solution without the need for additional connections between coil supports, and utilizing a recessed position for winding to avoid obstruction and enhance accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple connection members are used to join coil supports, then the stator can be assembled, but the device complexity and handling difficulty increase
Solution Approach 1:
The patent merges multiple separate connection members into a single continuous wire that winds through multiple coil supports sequentially. This continuous wire acts as a unified connection element that joins all coil supports without requiring separate connection members for each joint, thereby reducing overall device complexity while maintaining assembly capability.
Solution Approach 2:
The continuous wire maintains an unbroken path through all coil supports, creating a continuous electrical and mechanical connection. This continuity eliminates the need for discrete connection points and members, simplifying both the winding process and the final structure by removing unnecessary intermediate components.
2Volume of moving object
If coil supports are wound in nested position, then space is compact, but accessibility for winding operation is reduced
Solution Approach 1:
The coil supports are designed with dynamic positioning capability, allowing them to be temporarily moved from the nested position to an accessible position during the winding operation. After winding is complete, the supports return to the compact nested position. This dynamic adjustment resolves the contradiction between compactness and operational accessibility.
Solution Approach 2:
The coil supports are positioned in the accessible configuration before the winding operation begins, allowing easy access for the winding process. Once the winding is completed, the supports are then moved to the compact nested position. This preliminary positioning ensures that the winding operation can proceed efficiently without compromising final compactness.
3Reliability
If additional connection members are used between coil supports, then connections are secure, but magnetic losses due to short circuits increase
Solution Approach 1:
The patent combines multiple separate connection members into a single continuous wire that provides both mechanical support and electrical connection. This unified approach reduces the number of discrete connection points, thereby minimizing potential sites for magnetic short circuits and energy losses while maintaining secure connections through the continuous wire path.
Solution Approach 2:
The invention extracts and eliminates unnecessary connection members from the traditional multi-component assembly, retaining only the essential continuous wire that performs both mechanical and electrical functions. By removing redundant connection elements, the patent reduces potential sources of magnetic losses and short circuits between poles.
Data Source
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AI summary
The method involves winding two coil supports (14) using a continuous wire (52) in a withdrawal position in which monoblock support receiving arms (24) are removed from the coil supports, where the support receiving arms extend radially toward exterior of a monoblock ring (15) that is the form of a star package, of a stator (13). The coil supports are maintained at the ring by an annular element that is in the form of a ring package. The coil supports maintain the tension of wire strands in fitted position in which the coil supports are fitted on the ring. An independent claim is also included for a stator comprising a ring.