Winding Template for Electric Motor Stator Heat Dissipation
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Solution Overview
Problem
Existing methods for producing stators in electric motors face challenges such as limited coil packing density, inefficiencies in heat dissipation, and irregularities in bonding coil windings, which affect the motor's performance and durability.
Innovation Solution
A winding template with a receiving device and core that shapes the winding overhangs to reduce contact surfaces and enhance uniform heating, combined with metallic contact surfaces for targeted heat dissipation, allows for higher packing density and improved bonding of coil windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If coil wire is wound beyond the coil groove to increase packing density, then magnetic flux and motor performance are improved, but heat dissipation becomes irregular and bonding uniformity deteriorates
Solution Approach 1:
The winding template introduces locally different boundary surface geometries in specific areas where coil windings are formed. By creating polygon-shaped cross-sections with reduced contact surfaces at critical bonding locations, the template ensures uniform heat distribution and consistent bonding quality precisely where needed, while allowing increased coil packing density in other areas.
2Quantity of substance
If more coil turns are wound in the same space, then magnetic flux increases, but heat dissipation uniformity deteriorates
Solution Approach 1:
The winding template creates localized geometric variations in the form of polygon-shaped cross-sections at boundary surfaces. These local modifications reduce contact surfaces between the coil and template in specific high-heat areas, enabling uniform heat dissipation while maintaining high coil turn density throughout the winding structure.
3Power
If air cooling is used to dissipate heat from coil wire, then power delivery is improved, but coil wire abrasion occurs due to dust particles in cooling air
Solution Approach 1:
The invention accepts air cooling as the primary heat dissipation method but introduces a protective measure against its harmful effect. The winding template's polygon-shaped boundary surfaces create controlled contact reduction areas that prevent dust particle accumulation and reduce abrasion on coil windings, while maintaining effective air flow for heat dissipation and power delivery.
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
This approach enables a more compact, robust, and powerful electric motor with increased magnetic flux and torque, while reducing the motor's size and improving heat dissipation uniformity.
Implementation Method 1
metallic contact surfaces for targeted heat dissipation
Implementation Method 2
enhance uniform heating, combined with metallic contact surfaces for targeted heat dissipation
Data Source
Figure 1~2
Figure 3
AI summary
The winding template (40) has a magnet wire that is received in the coil space of a stator. A coil of the magnet wire is provided with two winding heads that is inserted into the coil space. A receiving unit (42) is arranged for accommodating the stator. A core (44) is fixed in the receiving unit during the insertion process of the magnet wire. A gap is formed between receiving unit and core in the region of the winding heads of the coil. The polygon-shaped boundary surfaces (48,68) of the gap are viewed in cross section. An independent claim is included for a method for manufacturing stator.