Adjustable Stator Insulation for Automatic Winding
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Solution Overview
Problem
Existing electric motor stator assemblies face challenges in securely attaching insulation members to components, which increases assembly costs and is incompatible with automatic winding processes due to the difficulty in securing insulation to stator teeth and bobbins.
Innovation Solution
An adjustable insulation member with a first and second configuration, allowing it to couple securely to stator teeth and extend between conduction coils and teeth, facilitating automatic winding and reducing assembly costs by being modular and tool-free.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional insulation members are used to insulate stator teeth, then electrical insulation is provided, but the insulation members are difficult to secure to the stator teeth and increase assembly cost
Solution Approach 1:
The insulation member is merged with the bobbin structure to form an integrated component. The bobbin serves dual functions: supporting the conduction coil and providing electrical insulation for the stator tooth. This integration eliminates the need for separate insulation members, reducing assembly complexity and cost while maintaining reliable electrical insulation.
Solution Approach 2:
The bobbin is designed with multi-functionality, serving both as a structural support for the conduction coil and as an electrical insulation barrier for the stator tooth. This universal component replaces multiple specialized parts, simplifying the assembly process and reducing manufacturing costs while ensuring proper electrical insulation.
2Reliability
If traditional insulation members are used, then electrical insulation is achieved, but they are incompatible with automatic winding processes
Solution Approach 1:
By merging the insulation function into the bobbin structure, the design enables compatibility with automatic winding processes. The integrated bobbin-insulation assembly can be automatically positioned and secured during machine winding operations, eliminating the need for manual insulation installation and enabling full automation of the winding process.
Solution Approach 2:
The bobbin structure is designed to automatically perform both coil support and electrical insulation functions during the winding process. The insulation member is pre-positioned on the bobbin, allowing it to self-secure during automatic winding operations without requiring additional manual intervention or complex securing mechanisms.
3Reliability
If separate insulation members are used, then electrical insulation is provided, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The insulation member and bobbin are merged into a single integrated component, reducing the total number of parts in the assembly. This simplification reduces assembly process complexity by eliminating the need to handle and secure separate insulation members, while maintaining reliable electrical insulation through the integrated design.
Solution Approach 2:
The multi-functional bobbin performs both structural support and electrical insulation roles, reducing device complexity by eliminating dedicated insulation components. This universal design simplifies the overall assembly structure and reduces the number of assembly steps required, while ensuring proper electrical insulation is maintained.
Data Source
AI summary
An insulation member for a stator assembly includes a first portion configured to couple to a first stator tooth and a second portion movably coupled to the first portion. The insulation member has a first configuration and a second configuration. The second portion is configured to move relative to the first portion when the insulation member moves between the first configuration and the second configuration. The second portion is configured to extend adjacent a second stator tooth when the first portion is coupled to the first stator tooth and the insulation member is in the second configuration.