Stator Winding Deflection for Automated Assembly
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Solution Overview
Problem
The existing stator designs for electric motors, particularly in pump units, face difficulties in automating the connection of winding wires to contact elements, making it challenging to insert the stator into a motor housing without requiring manual manipulation and specific recesses.
Innovation Solution
The stator design incorporates deflection elements that guide the winding wire from its exit point to the contact element in a straight or stretched manner, allowing for automated connection and insertion into a motor housing without the need for pressing manipulation, enabling one-handed handling and robotic automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If winding wires are routed to contact elements on the outer circumference of the stator, then electrical connection is achieved, but the stator cannot be pushed into a motor housing without recesses
Solution Approach 1:
The patent inverts the conventional arrangement by placing contact elements on the inner circumference of the stator instead of the outer circumference. This allows the stator to be pushed into a motor housing without requiring recesses, as the contact elements are positioned to face inward toward the rotor rather than outward toward the housing.
2Reliability
If connection wires are guided through complex paths to reach contact elements, then electrical connection is established, but automation of the assembly process becomes difficult
Solution Approach 1:
The patent incorporates deflection elements directly into the stator structure during manufacturing, creating pre-formed wire paths that guide connection wires from the stator winding to the contact elements. This preliminary structuring of the wire routing path eliminates the need for complex manual manipulation during assembly, enabling automated assembly processes.
Data Source
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AI summary
A stator of an electric motor with several stator windings arranged in a stator body (2) and electrical contact elements (42, 46) arranged on an end face of the stator body (2), to which each a winding wire of the stator winding is connected, wherein the winding wire (22, 24, 26, 28, 30, 32) is guided from the exit opening (10, 12, 14, 16, 18, 20) of the stator body around at least one deflecting element (50, 52, 56, 58, 60, 62, 64, 66) so that it extends from a position radially further inward than the inner base (44) of the contact element (42, 46) to the radial outside of the contact element (42, 46). The winding wire (22, 24, 26, 28, 30, 32) runs straight between the deflection element (50, 52, 56, 58, 60, 62, 64, 66) and another deflection point or the contact element (42, 46). A method for laying the winding wire of such a stator on the axial end face of the contact element arranged on the stator.