Stator Winding Aid Integrating Insulation and Wire Guidance
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Solution Overview
Problem
The existing stator manufacturing processes for electric motors are complex and laborious due to the need for separate components and assembly steps, particularly in winding and insulation, which complicates the winding process and assembly.
Innovation Solution
The stator design integrates the electrical insulation as a winding aid, allowing the winding wire to be guided through passages and clamped in depressions, eliminating the need for separate components and enabling a simpler, one-step winding process using an automatic needle winding machine, with insulation displacement contacts and indexing elements for circuit board and sensor fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate winding contact elements and insulating end plates are used, then the stator can be manufactured with proper insulation and winding structure, but the manufacturing process becomes complex and laborious
Solution Approach 1:
The patent combines the insulating end plate and the winding aid into a single integrated component. The winding aid is directly formed as part of the insulating end plate structure, eliminating the need for separate winding contact elements. This merging reduces the number of components and assembly steps while maintaining both insulation quality and winding functionality.
Solution Approach 2:
The insulating end plate is designed to serve multiple functions simultaneously: it provides electrical insulation, acts as a winding aid with integrated passages for guiding the winding wire, and serves as a structural component of the stator. This multi-functionality eliminates the need for separate dedicated winding contact elements.
2Reliability
If multiple separate components are assembled before winding, then proper insulation and winding structure are achieved, but the winding process becomes more complex and time-consuming
Solution Approach 1:
The winding aid passages are pre-formed as integral parts of the insulating end plate during its manufacturing process. This preliminary action ensures that the winding wire guidance paths are already in place before the winding operation begins, eliminating the need for separate assembly of winding contact elements and enabling faster winding.
3Reliability
If different winding wires are used for individual phases with separate passages, then proper phase insulation is achieved, but the winding process becomes complex and cumbersome
Solution Approach 1:
The winding aid is divided into multiple separate passages, with each passage dedicated to guiding a specific phase's winding wire. This segmentation allows different winding wires for different phases to be routed independently through dedicated paths, maintaining proper phase insulation while simplifying the winding process by providing clear, separate guidance for each phase.
Data Source
Figure 1
Figure 1
Figure 2~5
AI summary
The stator has a stator body (1), and an insulating unit that is provided with two passages for winding wire (9), where the passages are open in a direction on a ring (3) and an arm (4). The former passage is provided at the radial inner ring. The latter passage is assigned to the former passage. An independent claim is also included for a method for manufacturing a stator.