Annular Stator Insulation Structure for Easier Motor Assembly
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Solution Overview
Problem
Existing motor designs face challenges in maintaining insulation performance due to metallic foreign materials adhering to iron cores, which reduces the insulated state, and also suffer from decreased ease of assembly due to the design of insulating films and members.
Innovation Solution
The motor design incorporates an annular stator unit with iron cores having arc-shaped core-back portions and tooth portions, where insulating films with extended lengths in the axial direction are used to improve insulation, and position fixing portions on the insulating members ensure proper alignment and fixation during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the length of insulating films in the axial direction is made longer than the length of iron cores to improve insulation performance, then the insulation between windings and iron cores is improved, but the ease of assembly is decreased because insulating members may be pushed away and detached from iron cores during insertion
Solution Approach 1:
Position fixing portions are provided on insulating members before assembly to preemptively prevent the problem of detachment during insertion. This preliminary structural design ensures that insulating members remain properly positioned on iron cores even when insulating films are inserted, thereby maintaining ease of assembly while achieving improved insulation performance.
2Ease of manufacture
If insulating members are disposed on iron cores with gaps to accommodate insulating films, then insulation can be inserted, but the position of insulating members is not fixed and they may be pushed away during assembly
Solution Approach 1:
Position fixing portions are locally provided at specific locations on insulating members where engagement with iron cores is needed. This localized structural feature maintains gaps for insulating film insertion while providing targeted position fixation, thereby simultaneously achieving ease of manufacture and position stability.
3Reliability
If metallic foreign materials adhere to iron cores due to magnetic attraction, then insulation performance is reduced, but extending insulating films axially does not adequately protect the inner circumferential surface where materials are attracted
Solution Approach 1:
The insulating film is extended in the axial direction rather than only in the radial direction, covering the inner circumferential surface of iron cores where metallic foreign materials are magnetically attracted. This dimensional extension of insulation coverage effectively protects against harmful material adhesion while maintaining insulation performance.
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 design enhances insulation performance by preventing metallic foreign materials from adhering to the iron cores and improves assembly ease by securely fixing insulating members to the iron core, preventing detachment during the insertion of insulating films.
Implementation Method 1
Because such metallic foreign materials are attracted to the inner side, in the radial direction, of each of the iron cores by the magnetic force of the rotor
Data Source
AI summary
A motor includes a stator unit formed by coupling plural stators to one another into an annular shape. Each of the stators has: an iron core having an arc-shaped core-back portion and a tooth portion protruding from the core-back portion, the iron core forming slot portions between the iron core and adjacent ones of the stators; insulating members disposed on both end portions, in the axial direction, of the iron core; insulating films disposed so as to be in contact with inner walls of the slot portions of the iron core; and a winding disposed in the slot portions and wound over the iron core with the insulating members and the insulating films interposed therebetween. In a portion of each of the insulating films that is in contact with the inner wall of the slot portion, at least a portion that is in contact with an outer circumferential surface of the tooth tip portion has a length in the axial direction longer than the length of the iron core in the axial direction. Each of the insulating members has position fixing portions that are engaged with the iron core to fix the position of the insulating member.