Torque Motor Stator Coil Holder for Axial Coil Assembly

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Solution Overview

Problem

Existing torque motors for aeronautical applications face challenges in manufacturing complexity, high scrap rates, poor electrical insulation, and high costs due to manual assembly processes, which preclude the use of ceramic-coated wires and complicate integration of stator coils into the stator magnetic circuit.

Innovation Solution

A torque motor design featuring a one-piece stator with radial teeth and a separate winding support that allows axial insertion of stator coils, providing electrical insulation and facilitating assembly, enabling the use of ceramic-insulated wires and automation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual assembly operations are used to integrate stator coils into the stator magnetic circuit, then assembly flexibility is maintained, but manufacturing time and cost increase significantly

Engineering Contradiction:

Improveassembly processVSAvoidmanufacturing time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The stator is divided into two separate components: a stator magnetic circuit and a stator coil holder. This segmentation allows the coil holder to be pre-assembled with coils using automated processes, then the complete assembly is integrated into the magnetic circuit, significantly reducing manual assembly time and cost.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The stator coils are pre-mounted onto the stator coil holder before the final assembly with the magnetic circuit. This preliminary action enables automated coil winding and positioning processes to be used, eliminating the need for manual coil integration and reducing manufacturing time.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If manual shaping and compaction of stator coils is performed, then coil integration is achieved, but scrap rate increases due to coil damage

Engineering Contradiction:

Improvecoil integrationVSAvoidcoil integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

By separating the coil holder from the magnetic circuit, the coils are protected during assembly. The coils remain mounted on the rigid coil holder structure, preventing the manual shaping and compaction operations that previously caused damage and high scrap rates.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The stator coil holder acts as an intermediary structure that protects the stator coils during assembly. The coils are integrated into the holder using gentle automated processes, and the complete assembly is then integrated into the magnetic circuit without subjecting the coils to damaging manual operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If ceramic-coated wires are used, then electrical insulation performance improves, but manufacturing complexity increases due to handling constraints

Engineering Contradiction:

Improveelectrical insulationVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The stator coil holder serves as a protective intermediary that accommodates ceramic-coated wires during assembly. The holder's structure allows automated handling of the fragile ceramic-insulated coils without damage, enabling the use of high-performance ceramic-coated wires while maintaining manufacturing simplicity through automation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The design simplifies assembly, reduces scrap rates, lowers manufacturing costs, and enhances electrical insulation, allowing operation in extreme temperatures and improved performance in aeronautical applications.

Implementation Method 1

This permanent magnetic field is generally generated by permanent magnets placed in the rotor or stator of the motor

Methodology Applied

Scientific EffectPermanent magnet: Magnetism

Implementation Method 2

Torque motors are electric motors that aim to obtain torque by the circulation of an electric current of predetermined intensity in coils placed in a permanent magnetic field

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP3432452B1Torque motor comprising a stator coil holder and a magnetic core including a permanent magnet

Publication Date: 2026.01.14 LIEBHERR AEROSPACE TOULOUSE

Figure 1~2
Figure 3a~3c
Figure 3d~5

AI summary

A radial air-gap coupled motor comprises a stator (10) and a rotor (20) extending along the same central axis (Z). The stator (10) comprises a single-piece magnetic body (11) with at least one pair of radial teeth (12) extending along the central axis (Z) and defining slots (15, 16) for receiving stator coils (32, 33) and at least one permanent magnet (13, 14) carried by said single-piece magnetic body (11) and it comprises a winding support (30) for the stator coils (32, 33) consisting of a hollow body (34) extending along the central axis (Z) and delimiting a housing (35) for receiving said rotor (20) and housings (41, 42) for receiving said stator coils (32, 33). The integration of the stator coils (32, 33) into said stator (10) consists of axially inserting said winding support (30) equipped with said stator coils (32, 33) into said monobloc magnetic body (11).