GB2610874A - Stator assembly method - Google Patents
Stator assembly method Download PDFInfo
- Publication number
- GB2610874A GB2610874A GB2113457.2A GB202113457A GB2610874A GB 2610874 A GB2610874 A GB 2610874A GB 202113457 A GB202113457 A GB 202113457A GB 2610874 A GB2610874 A GB 2610874A
- Authority
- GB
- United Kingdom
- Prior art keywords
- stator core
- stator
- winding
- core body
- pole
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000000034 method Methods 0.000 title claims abstract description 30
- 238000004804 winding Methods 0.000 claims abstract description 42
- 238000005096 rolling process Methods 0.000 claims abstract description 10
- 230000015572 biosynthetic process Effects 0.000 claims abstract description 6
- 238000005755 formation reaction Methods 0.000 claims abstract description 6
- 240000008042 Zea mays Species 0.000 claims 1
- 235000005824 Zea mays ssp. parviglumis Nutrition 0.000 claims 1
- 235000002017 Zea mays subsp mays Nutrition 0.000 claims 1
- 235000005822 corn Nutrition 0.000 claims 1
- 238000009413 insulation Methods 0.000 abstract 1
- 238000004519 manufacturing process Methods 0.000 description 4
- 230000000295 complement effect Effects 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 238000013459 approach Methods 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000009429 electrical wiring Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 238000002955 isolation Methods 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 229910000679 solder Inorganic materials 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K1/00—Details of the magnetic circuit
- H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
- H02K1/12—Stationary parts of the magnetic circuit
- H02K1/14—Stator cores with salient poles
- H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
- H02K1/148—Sectional cores
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
- H02K15/021—Magnetic cores
- H02K15/022—Magnetic cores with salient poles
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
A method of assembling an electric machine stator, by providing a stator core 110 in an initial linear configuration (Fig. 2A) with pole teeth 150 extending from the top 141 surface; winding a coil on each pole tooth; rolling the stator core to deform the stator core body into an annular configuration (Fig. 2B). After rolling, the bottom surface 142’ of the stator core may be circular, and the stator core between adjacent pole teeth may be arcuate. The ends 191, 192 of the body may abut, and have interconnecting formations 196, 197 which latch together. The winding of the coils (130, Fig. 3) may use a movable needle winding assembly (220 and 230, Fig. 3) with a supply of wire (210, Fig. 3), which is moved around the pole teeth. There may be insulation between the teeth and the winding.
Description
Stator Assembly Method
Field of Invention
The present invention relates to methods of assembling stators for electric machines and stators and electric machines associated therewith.
Background
Electric machines (which it will be appreciated is used as a general term for a machine which uses electromagnetic forces such as an electric motor or generator) may consist of a stator and a rotor and operate through the interaction of the machines magnetic field.
A common stator configuration comprises a laminated body (which may, for example, be stamped from steel) defining a generally annular body with a plurality of radially extending pole teeth. Each pole tooth is surrounded by an electrical winding in the assembled electric machine. Manufacturing cost and speed is a key consideration in the design of electrical machines and as such a number of different stator assembly methods have been proposed.
In some arrangements, stator pole teeth may be provided with electrical windings which are pre-wound before being positioned onto a pole tooth (for example being slid onto the tooth in a radial direction). In order to assist such an approach a segmented stator core may be provided which can be placed into an open configuration to aid access to the pole tooth before being closed to have an annular arrangement.
Another way to automate the assembly of a stator is to use a needle winding apparatus to form the wire windings directly around the pole teeth of the stator core.
A needle winding assembly may use positionable winding head comprising a wire dispensing nozzle at the tip of a needle assembly. In use, the winding head positions the nozzle adjacent to a pole tooth to be wound such that the needle assembly projects into the space between adjacent pole teeth. By moving the nozzle relative to the pole tooth an electrical winding may be built up on the pole tooth.
There remains a desire to provide further improvements in methods of manufacturing stator assemblies. For example, it would be desirable to provide methods which enable shorter total assembly time. The precision of the placing of wire strands forming the electrical windings may also impact the final performance of the electric machine -for example, it is desirable to maximise the fill factor of the coil and avoid unused space around the pole teeth.
Summary of Invention
According to one aspect of the invention, there is provided a method of assembling a stator, the method comprising the steps of: providing a stator core in an initial configuration, comprising an elongate linear stator core body extending from a first end to a second end and having an opposing top and bottom surfaces extending lengthwise therebetween wherein a plurality of pole teeth extend from the top surface in a generally perpendicular orientation to the lengthwise direction; holding the stator in said initial configuration; providing a coil winding on each pole tooth; rolling the stator core to deform the stator core body into a closed annular configuration in which each pole tooth extends generally radially from the stator core body.
Advantageously, the applicant has recognised that for smaller sized stators it is possible to form the stator core initially as a simple linear form, provide coil windings on the pole teeth and then bend the body of the stator core into its final annular form. This provides a simple and efficient manufacturing approach which is well suited to automation.
The stator core body may be deformed by rolling the bottom surface of the stator core body into a circular form.
Rolling the stator core may deforms the stator core body between adjacent pole teeth into an arcuate section.
Methods of the invention may be particularly suited to relatively thin stator cores which are more easily plastically deformed. The thickness of the stator core body (between the top and bottom surfaces) may for example be no more than 15mm. It may be appreciated that the thickness between the top and bottom surfaces corresponds to the radial thickness of the stator core body in the final annular configuration. The thickness may be less than 10mm, for example less than 5mm.
In the closed annular configuration the first and second ends of the stator core body abut. The method may further comprise latching the ends of the stator core body in the closed annular configuration. The stator core may, for example, comprises interconnecting formations at each linear end and wherein in the closed annular configuration the interconnecting formations latch together. In some embodiments one end of the stator core may include a latch arm and the other end of the stator core body may comprise a recess for receiving the latch arm. The interconnecting formations may be proximal to the bottom surface of the stator core body (such that they are on the opposite side to the pole teeth.
In some embodiments the step of providing a coil winding on each pole tooth may comprise positioning a pre-wound coil on an insulating bobbin onto each tooth. Such an arrangement is shown for example in the applicant's earlier UK Patent application GB2102330.4 (filed 19th February 2021). In other embodiments the coil winding may comprise providing a needle winding assembly comprising a supply of wire, and a positionable winding head comprising a wire dispensing nozzle at the tip of a needle assembly; driving the needle assembly relative to the stator core to form an electrical winding of wire around a pole tooth of the core; and repeating the step of driving the needle assembly to form an electrical winding around each pole tooth of the core.
The applicant has recognised that a method in accordance with embodiments may provide advantages over existing needle winding methods for stator assembly such as enable increased coil fill and/or decreasing manufacturing time. For example, in conventional needle winding methods the needle size and dimensions of the space between adjacent pole teeth may provide a spatial limitation during winding which must be allowed for. As a result the needle size may result in a limitation on how close the winding can be relative to the ends of the pole teeth. Embodiments of the invention may ameliorate such problems by increasing the space available around the pole tooth for the needle assembly to operate in due to the provision of an open configuration to the stator core.
The method may further include the step of providing an insulating layer on the array of pole teeth prior to forming a wire coil around the pole teeth.
A further aspect of the invention comprises a stator assembly manufactured in accordance with the embodiments of the invention.
Whilst the invention has been described above, it extends to any inventive combination of the features set out above or in the following description or drawings.
Description of the Drawings
Embodiments of the invention may be performed in various ways, and embodiments thereof will now be described by way of example only, reference being made to the accompanying drawings, in which: Figure 1A show an electrical machine in accordance with an embodiment; Figures 2A shows an end view of the stator core in an open configuration in accordance with an embodiment; Figure 2B shows the stator core of figure 2 being transformed from an open to a closed configuration; Figure 3 shows a schematic representation of a needle assembly forming an electrical winding of wire around a pole tooth of the stator core; and Figures 4 illustrates the method in accordance with an embodiment.
Detail Description of Embodiments
It may be noted that directional/orientational terms such as radial, circumferential and axial may be used herein to refer to the general directions of the assembly or components thereof relative to their in-use configuration. The general directions are shown, by way of example only, by arrow R showing a radial direction, C showing a circumferential direction and A showing an axial direction in Figure 1. However, the skilled person will appreciate that (unless expressly indicated otherwise) such directions are used broadly and do not imply strict mathematical conformance with a particular orientation. Likewise, the use of such terminology does not exclude a component or feature having a non-circular or irregular form.
An electric machine 1 is shown in figure 1 and comprises a stator 100 surrounding a rotor 200. The stator comprises a stator core 110 and a plurality of coils 130. Each coil is mounted around a poles 150 of the stator core 110.
A side view of a stator core 110 in accordance with an embodiment is shown in isolation in figure 2. In the final, in use configuration the stator core 110 is formed into a closed annular loop. Figure 2A shows the stator core 110 in an initial open configuration (for clarity the length of the core has been interrupted in the figure). The stator core may, for example, be initially formed in this configuration. As will be known in the art, the stator core 110 may be formed from metal laminations which are stamped into the required shape. In this initial configuration the body 140 of the stator core 110 has a generally linear elongate form and extends from a first end 191 to a second end 192. The stator core body 140 has a thickness t measured between opposing top 141 and bottom 142 surfaces. Each pole tooth 150 projects perpendicularly away from the top surface 141 of the stator core body 140. It will be appreciated that top and bottom in this context are non-limiting with the top surface merely being used to refer to the surface having the pole teeth 150.
In the assembled configuration (as in Fig 1) the stator core 110 is rolled into a condition in which the body 140 forms an annular shape and the pole teeth 150 each project radially away from the body 140. The transition between these two configurations is shown in Figure 2B in which the left-hand side of the stator core 110 has not yet been deformed but the right-hand side has been rolled into its final shape. It can be seen that in this assembled configuration the relatively thin webs of material defining the sections of the stator core body 140 between adjacent pole teeth 150 is bent into an arcuate form. The bottom surface 142' of the stator core body is formed into a circumferentially extending circular surface by the deformation. Importantly it can be noted from this figure that the space between adjacent pole teeth 150 is reduced in the closed configuration due to the radial orientation of the pole teeth 150.
It may be noted that the ends 191, 192 of the stator core body 140 in figure 2 are provided with complementary engagement features. This may provide a stator core 110 which can be resiliently engaged in its closed annular configuration without the need for additional processing steps such as applying a bead of solder or welding and/or may provide a stator core 110 which accurately self-aligns in the closed configuration. The complementary engagement features 196 and 197 may comprise a latch arm 196 projecting from one end 191 and a recess 197 formed in a surface of the other end 192 into which the head of the arm 196 can be coupled.
Figure 3 illustrates the winding of a coil 130 onto a pole tooth 150 in accordance with embodiments. A coil winding apparatus 200, includes a supply of electrical wiring 210 which is supplied to a positionable winding head 220. The winding head 220 may for example have multiple axis of movement relative to the stator core 110. The winding head 220 includes a needle assembly 230 which extends longitudinally away from the winding head 220 and has a wire dispensing nozzle 235 at its distal tip. Typically the wire dispensing nozzle 235 extends transversely from the needle assembly 230 to direct the wire accordingly. During the assembly process the needle assembly 230 can be positioned relative to the pole tooth 150 and a feed of wire 215 can be wound around the tooth 150 by relative movement between the stator core and needle assembly 230 until a coil winding 130 has been formed on the pole tooth 150.
Advantageously, as the stator core 110 is in an open/linear configuration during this process the space between adjacent teeth 150 is increased to provide improved access for the needle assembly 230. In particular, it may be noted that the tip portions 160 which extend laterally from the ends of each tooth 150 are closely aligned when the stator core 110 is in the annular configuration.
The method of assembly in accordance with an embodiment is shown in the flow chart of Figure 4. In step 410 a stator core is provided and comprising an array of pole teeth connected to a stator core body in an initial linear form. In step 420, the stator core is held in this open configuration, for example being placed in an alignment jig, in which the stator core body extends along a linear direction and each pole tooth extending perpendicular to the linear direction body. In step 430, the needle winding assembly is used to wind the electrical windings of the stator around each pole tooth of the core. This step is typically a repeating process winding each pole tooth in sequence until all the pole teeth are wound. Finally, in step 440 the stator core is closed by deflecting the stator core to roll the stator core body into a closed annular configuration in which each pole tooth extends generally radially from the stator core body. In rolling the stator core the complementary engagement features at the ends of the stator core body may be brought into engagement to retain the stator core in its final configuration.
Although the invention has been described above with reference to preferred embodiments, it will be appreciated that various changes or modification may be made without departing from the scope of the invention as defined in the appended claims. For example, whilst the illustrated embodiment described above comprises an internal rotor and external stator embodiments of the invention need not be limited to such an arrangement. In this regard the skilled person will appreciate that some motors use a stator having an internal annular stator core with outwardly projecting pole teeth. It will be appreciated that embodiments of the present disclosure can easily be adapted to such an arrangement without the departing from the scope of the invention. For example by simply deforming the stator core such that the bottom surface becomes the radially inner surface after installation a final stator configuration will be provided in which the pole teeth are external.
Claims (9)
- Claims 1 A method of assembling a stator, the method comprising the steps of: providing a stator core in an initial configuration, comprising an elongate linear stator core body extending from a first end to a second end and having an opposing top and bottom surfaces extending lengthwise therebetween wherein a plurality of pole teeth extend from the top surface in a generally perpendicular orientation to the lengthwise direction; holding the stator in said initial configuration; providing a coil winding on each pole tooth; rolling the stator core to deform the stator core body into a closed annular configuration in which each pole tooth extends generally radially from the stator core body.
- 2. The method of claim 1, wherein rolling the stator core to deform the stator core body comprises rolling the bottom surface of the stator core body into a circular form.
- 3. The method of claim 1 or 2, wherein rolling the stator core deforms the stator core body between adjacent pole teeth into an arcuate section.
- 4. The method of claim 1, 2 or 3, wherein the thickness of the stator core body between the top and bottom surfaces is no more than 15mm.
- 5. The method of any preceding claim, wherein in the closed annular configuration the first and second ends of the stator core body abut.
- 6 The method of claim 5, wherein the stator core comprises interconnecting formations at each end and wherein in the closed annular configuration the interconnecting formations latch together.
- 7 The method of cany preceding claim, wherein the step of providing a coil winding on each pole tooth corn prises: providing a needle winding assembly having a supply of wire, and a positionable winding head comprising a wire dispensing nozzle proximal to the tip of a needle assembly; driving the needle assembly relative to the stator core to form an electrical winding of wire around a pole tooth of the core; repeating the step of driving the needle assembly to form an electrical winding around each pole tooth of the core.
- 8. The method of claim 7, further comprising the step of providing an insulating layer on the array of pole teeth prior to forming a wire coil around the pole teeth.
- 9. A stator assembly formed by the method of any preceding claim.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB2113457.2A GB2610874A (en) | 2021-09-21 | 2021-09-21 | Stator assembly method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB2113457.2A GB2610874A (en) | 2021-09-21 | 2021-09-21 | Stator assembly method |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| GB2610874A true GB2610874A (en) | 2023-03-22 |
Family
ID=85289061
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB2113457.2A Pending GB2610874A (en) | 2021-09-21 | 2021-09-21 | Stator assembly method |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2610874A (en) |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2174552A (en) * | 1985-03-28 | 1986-11-05 | Gen Electric | Dynamoelectric machines |
| EP0652622A2 (en) * | 1993-11-08 | 1995-05-10 | Mitsubishi Denki Kabushiki Kaisha | Rotary motor and production method thereof, and laminated core and production method thereof |
| EP0871282A1 (en) * | 1997-04-11 | 1998-10-14 | Kabushiki Kaisha Toshiba | Stator for dynamoelectric machine and method of making the same |
| DE19851363A1 (en) * | 1998-11-09 | 2000-05-18 | Daimler Chrysler Ag | Method of manufacturing a stator for an electric motor |
| WO2001095459A1 (en) * | 2000-06-06 | 2001-12-13 | Newage International Limited | A stator for an electrical machine |
| EP2472704A2 (en) * | 2010-12-29 | 2012-07-04 | Samsung Electronics Co., Ltd. | Motor, manufacturing method for the same and washing machine |
-
2021
- 2021-09-21 GB GB2113457.2A patent/GB2610874A/en active Pending
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2174552A (en) * | 1985-03-28 | 1986-11-05 | Gen Electric | Dynamoelectric machines |
| EP0652622A2 (en) * | 1993-11-08 | 1995-05-10 | Mitsubishi Denki Kabushiki Kaisha | Rotary motor and production method thereof, and laminated core and production method thereof |
| EP0871282A1 (en) * | 1997-04-11 | 1998-10-14 | Kabushiki Kaisha Toshiba | Stator for dynamoelectric machine and method of making the same |
| DE19851363A1 (en) * | 1998-11-09 | 2000-05-18 | Daimler Chrysler Ag | Method of manufacturing a stator for an electric motor |
| WO2001095459A1 (en) * | 2000-06-06 | 2001-12-13 | Newage International Limited | A stator for an electrical machine |
| EP2472704A2 (en) * | 2010-12-29 | 2012-07-04 | Samsung Electronics Co., Ltd. | Motor, manufacturing method for the same and washing machine |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US10910928B2 (en) | Stator assembly method and stator assembly apparatus | |
| US10594182B2 (en) | Stator manufacturing method and stator | |
| US7348706B2 (en) | Stator assembly for an electric machine and method of manufacturing the same | |
| CN102934331B (en) | Electromagnet for stator and method of manufacturing electromagnet for stator | |
| US9634548B2 (en) | Method for manufacturing an armature winding for an electric machine | |
| KR102274082B1 (en) | Stator, method for manufacturing stator, coil, and method for manufacturing coil | |
| EP2680412B1 (en) | Arrangement of coil wires in a rotor of an electric motor | |
| US20160099616A1 (en) | Iron core member, inner rotor type stator for rotating electrical machine, and method for manufacturing inner rotor type stator for rotating electrical machine | |
| US10594183B2 (en) | Stator assembling method | |
| KR20030087062A (en) | Stator for inner rotor motors and method of producing the same | |
| JP2013121296A (en) | Stator, manufacturing method of stator, and manufacturing apparatus for stator | |
| JPH11299132A (en) | Motor stator core | |
| US20100236059A1 (en) | Stator manufacturing apparatus | |
| EP2937978B1 (en) | Method for manufacturing stator for rotating electrical machine | |
| KR20130028566A (en) | Stator and methed for manufacturing of stator and electric motor having thereof, electric vechile having electric motor | |
| JP5768305B1 (en) | Stator manufacturing method and apparatus | |
| GB2610874A (en) | Stator assembly method | |
| EP2083505A1 (en) | Dynamo-electric machine with tooth-wound coils mounted on coil bodies | |
| JP4475108B2 (en) | Segment type stator structure and manufacturing method thereof | |
| JP2003070201A (en) | Stator for rotating electric machine and method of manufacturing the same | |
| JP2010004721A (en) | Method of manufacturing coil assembly of rotary electric machine | |
| CN114450874A (en) | Method for manufacturing coil for motor, method for manufacturing motor, and apparatus for manufacturing coil for motor | |
| WO2023091593A1 (en) | Method for external winding of esp motor using a split core stator | |
| US20190305621A1 (en) | Wound coil, coil for electrical rotating machine, electrical rotating machine, method for manufacturing wound coil, and apparatus for manufacturing wound coil | |
| JP2008172863A (en) | Rotating electric machine and manufacturing method thereof |