Stator Winding Linear-to-Cylindrical Conversion
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Solution Overview
Problem
The existing methods for winding wires in stator packs of continuous hairpin type electric motors face challenges in achieving cylindrical geometry with necessary twists and precise positioning between stator teeth, leading to time-consuming, complicated, and costly processes with unsatisfactory results.
Innovation Solution
A method and processing line that involves winding wires around linear supports with specific pitches, pressing, rolling into cylindrical form, and inserting stator teeth to create precise cylindrical windings, ensuring optimal pitch management and high precision in the production of stator packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If wires are woven after being placed along a cylindrical surface in the prior art, then cylindrical geometry with twists can be obtained, but the process becomes time-consuming, complicated and expensive
Solution Approach 1:
The patent applies preliminary action by first winding wires linearly around a support to create a preliminary winding structure, then subsequently forming this structure into the final cylindrical shape. This preliminary linear winding step simplifies the overall process by breaking down the complex cylindrical winding into manageable sequential steps, thereby reducing production time and complexity while maintaining the required cylindrical geometry with twists
2Shape
If wires are woven after being placed along a cylindrical surface in the prior art, then cylindrical geometry with twists can be obtained, but the process becomes complicated and expensive
Solution Approach 1:
The patent applies segmentation by dividing the winding process into distinct sequential stages: first creating a preliminary linear winding around a support, then forming the cylindrical shape, and finally applying twists. This segmentation transforms a single complex cylindrical winding operation into multiple simpler, manageable steps, reducing device complexity and making the process more controllable and less expensive
3Shape
If wires are woven after being placed along a cylindrical surface in the prior art, then cylindrical geometry can be obtained, but positioning precision between stator teeth is not satisfactory
Solution Approach 1:
The patent applies preliminary action by first creating a linear winding structure around a support with precisely controlled pitch, then forming this pre-positioned structure into the final cylindrical shape. This preliminary linear winding establishes accurate wire positioning before the complex cylindrical forming step, ensuring that wires are correctly positioned relative to stator teeth while achieving the required cylindrical geometry
4Manufacturing precision
If optimal management of wire pitch is required during the entire production cycle, then high precision windings can be achieved, but the process becomes more complex
Solution Approach 1:
The patent applies segmentation by separating pitch control into distinct phases: pitch is controlled during the linear winding phase around the support, then maintained during the cylindrical forming phase. This segmented approach to pitch management allows for simple, effective control of wire spacing throughout the process, achieving high winding precision without requiring complex integrated control systems
Solution Approach 2:
The patent applies parameter changes by controlling the winding pitch as a key parameter during the linear winding phase, then maintaining this pitch parameter through the cylindrical forming phase. By focusing pitch control on the preliminary linear winding step and maintaining it through subsequent operations, the patent achieves high precision windings using simple, manageable parameter control rather than complex multi-parameter systems
Data Source
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AI summary
A method for providing the winding of a plurality of wires within a stator pack (S) of a stator for electric motors, characterized in that it comprises: - a winding phase, in which at least one linear winding of woven wires (V1, V2, V3) around a linear support (11, 11') is provided; - a winding release step, in which the linear support (11, 11') is extracted from the inside of the at least one linear winding of woven wires (V1, V2, V3); - a pressing step, in which the at least one linear winding of woven wires (V1, V2, V3) is pressed transversely; - a rolling step, in which the at least one linear winding of woven wires (V1, V2, V3) is curved along a cylindrical surface (31, 31') by rolling it around a roller (33, 33') so as to convert it into at least one cylindrical winding of woven wires (C1, C2, C3); - a winding repositioning step, and - a step for the insertion and fixing of the stator teeth (D). The present invention also relates to a processing line for the provision of the method.