Annular Coil Unit Stator Layout for Reduced Axial Thickness
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Solution Overview
Problem
Existing stators and motors tend to be thick in the axial direction due to the placement of busbars above the windings, which limits their thinning and miniaturization.
Innovation Solution
A stator design featuring a coil unit assembly with busbars positioned on the outer peripheral surface, allowing for a thinner axial profile. The coil units include split cores, insulators, and windings arranged in a delta connection with parallel circuits, enabling efficient electrical connections while minimizing axial thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If busbars are provided above the windings in the axial direction, then the number of connection points between the windings and the busbars can be small, but the armature tends to be thick in the axial direction
Solution Approach 1:
The busbar is repositioned from the axial direction (above the windings) to the radial direction (on the outer peripheral surface of the coil unit assembly). This dimensional change allows the busbar to connect to multiple windings simultaneously while reducing the axial thickness of the armature.
Solution Approach 2:
Multiple connection points are merged into a single radial position on the outer peripheral surface. The busbar in this position can electrically connect to multiple windings (U-phase, V-phase, W-phase) at the same time, reducing the overall complexity of connections while maintaining electrical functionality.
2Length of moving object
If the stator and motor are thinned in the axial direction, then miniaturization is achieved, but the electrical connections must be reconfigured
Solution Approach 1:
The electrical connection configuration is simplified by moving the busbar to the radial direction. This allows multiple windings to be connected in parallel through a single radial busbar position, reducing the complexity of electrical connections while enabling axial thinning.
Solution Approach 2:
The busbar on the outer peripheral surface serves multiple functions simultaneously: it provides electrical connections for multiple phases (U, V, W), acts as a structural element on the coil unit assembly, and enables the thinning of the armature in the axial direction. This multi-functionality reduces the need for separate connection components.
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 proposed stator and motor design achieves axial thinning while maintaining efficient electrical connections, facilitating miniaturization and potentially reducing manufacturing costs.
Implementation Method 1
a coil that includes a winding wound around the tooth of the split core with the insulator interposed therebetween
Data Source
AI summary
A device may include a coil unit assembly that includes a first, second, and third coil unit annularly arranged. Further, may include a busbar provided on an outer peripheral surface of the coil unit assembly, wherein when a direction in which an axis of the stator extends is defined as an axial direction, a direction which is orthogonal to the axial direction and in which outer peripheral surface and inner peripheral surface of the stator face each other is a radial direction, and a direction along an outer periphery of the stator when viewed from the axial direction is a circumferential direction, wherein the coil units each include a split core that includes a tooth that extends in the radial direction, an insulator mounted to overlap at least the tooth of the split core, and a coil that includes a winding wound around the tooth of the split core with the insulator interposed therebetween.