Stator Winding with Continuous Wire and Conductive Sheets
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Solution Overview
Problem
Existing motor stator winding methods result in significant wire waste and complex assembly processes due to the need for frequent cutting of conductive wires and cumbersome connections to an external power source.
Innovation Solution
A stator design featuring windings guided by conductive sheets and wire clips, allowing a single conductive wire to be wound continuously and divided into groups for short-circuit connections to an external power source, eliminating the need for wire cutting and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a single conductive wire is wound continuously without cutting, then wire waste is reduced and material efficiency is improved, but the complexity of connecting windings to external power source increases
Solution Approach 1:
The stator windings are divided into multiple groups, with each group containing multiple coil groups. Conductive sheets are used to short-circuit connect windings within each group, while conductive wires connect different groups to external power sources. This segmentation allows continuous winding to be managed in organized sections, reducing wire waste while maintaining manageable connection complexity.
Solution Approach 2:
Conductive sheets are introduced as intermediary elements between the continuously wound conductive wire and the external power source. These sheets facilitate the connection of multiple windings without requiring frequent cutting of the main conductive wire, thus reducing wire waste while simplifying the overall connection process through a standardized intermediate component.
2Ease of manufacture
If conductive wires are cut frequently during winding, then assembly and connection to external power source becomes simpler, but significant wire waste occurs
Solution Approach 1:
Conductive sheets are pre-prepared with appropriate configurations before the winding process. These pre-fabricated conductive sheets are then used to connect the continuously wound conductive wire to external power sources, eliminating the need for frequent cutting during winding while maintaining assembly simplicity through pre-organized connection points.
Solution Approach 2:
Instead of discarding excess wire from frequent cutting operations, the invention uses a single continuous conductive wire that is wound without cutting. The wire is recovered and reused continuously throughout the winding process, with only minimal wire ends requiring connection through conductive sheets, thus dramatically reducing wire waste.
3Productivity
If multiple cutting operations are performed on conductive wire, then winding can be completed, but the process becomes time-consuming and reduces productivity
Solution Approach 1:
The winding process is made continuous by using a single conductive wire that is wound without cutting or interrupting the flow. This continuous winding action eliminates the time lost in repeated cutting operations, significantly improving productivity while maintaining winding quality through the consistent continuous process.
Solution Approach 2:
The conductive wire is prepared in advance as a single long continuous piece, eliminating the need for repeated cutting operations during the winding process. This preliminary preparation of the wire allows the winding operation to proceed continuously without time-consuming interruptions for cutting and repositioning.
4Ease of operation
If windings are divided into multiple groups with short-circuit connections, then connection to external power source is simplified, but the stator structure becomes more complex
Solution Approach 1:
Conductive sheets serve multiple functions: they short-circuit connect windings within groups, provide connection points for external power sources, and organize the stator winding structure. This multi-functionality simplifies the overall connection process while avoiding the need for separate components for each function, thus reducing operational complexity despite the grouped structure.
Solution Approach 2:
The functions of winding connection, short-circuiting, and external power source connection are merged into integrated conductive sheet assemblies. These combined components simplify the overall stator structure by eliminating the need for separate elements for each function, making the grouped winding structure easier to operate and connect while managing structural complexity through integration.
Data Source
AI summary
A stator and a motor including the motor are disclosed. The stator includes a number of windings and a number of guiding portions. The windings are formed by winding a single conductive wire under the guide of the guiding portions. The windings are divided into multiple groups, and the windings in each group are short-circuit connected with each other.