Manufacturing method of stator, stator of electric motor, electric motor, hermetically sealed compressor, and refrigeration cycle apparatus
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Solution Overview
Problem
Existing stator winding methods for rotating electric machines require deformation of the annular yoke into a non-circular shape to widen gaps for winding, making it impossible to wind multiple teeth simultaneously with multiple nozzles, thus increasing time and risk of connecting wire loss.
Innovation Solution
A manufacturing method that uses multiple winding nozzles to wind adjacent teeth simultaneously by opening a connected stator core into a C-shape, then closing it to form a circle, with the winding nozzle passing through recessed insulator portions and laying the connecting wire over stepped portions to ensure tight contact with insulators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the annular yoke is deformed into a non-circular shape to widen gaps between teeth, then it is possible to pass windings through the gaps, but it becomes impossible to wind multiple adjacent teeth simultaneously using multiple winding nozzles
Solution Approach 1:
The stator core is designed with a movable portion that can be shifted in the circumferential direction. During winding, the movable portion is positioned to widen the gap between teeth, allowing winding nozzles to pass through. After winding, the movable portion returns to its original position, forming a circular annular shape. This dynamic adjustment enables both easy winding and simultaneous multi-tooth winding operations.
Solution Approach 2:
The stator core is divided into a fixed portion and a movable portion. The movable portion can be independently shifted circumferentially to adjust gap widths between teeth. This segmentation allows different parts of the stator core to serve different functions: the fixed portion maintains structural integrity while the movable portion enables gap adjustment for winding operations.
2Ease of manufacture
If the annular yoke is deformed into a non-circular shape to enable winding, then windings can be passed through gaps, but the connecting wire may loose due to repeated deformation
Solution Approach 1:
The stator core is divided into a fixed portion and a movable portion. The movable portion is the only part that deforms during winding, while the fixed portion and the connecting wires remain stationary. This segmentation isolates the deformation to a specific region, preventing stress concentration on the connecting wires and reducing the risk of wire loosening.
Solution Approach 2:
The movable portion acts as an intermediary element that facilitates the winding process by temporarily widening gaps. It absorbs the mechanical stress of deformation and protects the connecting wires from direct stress, allowing the winding operation to proceed without compromising wire stability.
3Productivity
If multiple winding nozzles are used to wind adjacent teeth simultaneously, then winding time is reduced, but the stator core must maintain a C-shape which complicates the structure
Solution Approach 1:
The stator core transitions between two states: a C-shape state during winding that allows multiple nozzles to access adjacent teeth simultaneously, and a circular state during operation that provides structural stability. The movable portion enables this dynamic shape change without adding permanent structural complexity.
Solution Approach 2:
The shape parameter of the stator core is changed temporarily during the winding process. The movable portion is shifted to create a C-shape configuration, enabling simultaneous multi-tooth winding. After winding completion, the movable portion returns to its original position, restoring the circular shape and eliminating the temporary structural modification.
Data Source
AI summary
A manufacturing method of a stator includes: performing winding and laying a connecting wire. The performing winding and the laying the connecting wire are alternately repeated. In the performing winding, the winding to be in contact with portions of the insulators that are located opposite to the back yokes is wound such that a distal end of the winding nozzle is caused to pass through an inside of the recessed insulator portion, while the winding led out from the distal end of the winding nozzle is being laid over a stepped portion.