Armature Bobbin Segmented Contact Insulation Heat Dissipation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing bobbin structures in armatures suffer from deteriorated insulation properties between adjacent coils, leading to potential ground faults and reduced efficiency in heat dissipation and fill factor, especially when resin molding is applied.
Innovation Solution
A bobbin structure for a three-phase motor with 6N slots and 3N coils per phase, featuring a main pole with a winding bobbin and an auxiliary pole with an empty bobbin, where the empty bobbin and winding bobbin contact each other on both outer and inner peripheral sides, forming a contact portion that enhances insulation and allows resin molding, thereby improving heat transfer and insulation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flange portions are placed to overlap at bottom portions of coil bobbins to increase insulation distance, then insulation distance between coil and core is improved, but heat dissipation efficiency deteriorates due to reduced contact area
Solution Approach 1:
The bobbin structure is segmented into multiple contact portions along the slot length direction. Instead of relying on a single overlapping flange portion, multiple contact portions are distributed along the slot, allowing heat dissipation to occur at multiple locations while maintaining insulation distance through the bobbin wall structure.
Solution Approach 2:
The solution transitions from a single-point contact (overlapping flange portions) to a distributed linear contact along the slot length. By extending the contact area along the longitudinal dimension of the slot, heat dissipation efficiency is improved without compromising the insulation distance provided by the bobbin structure.
2Productivity
If coil bobbins are positioned to maximize fill factor, then space efficiency is improved, but insulation properties between adjacent coils deteriorate
Solution Approach 1:
Empty bobbins are introduced as intermediary structures between adjacent coil bobbins. These empty bobbins act as insulation barriers that prevent direct contact between adjacent coils, maintaining reliable insulation properties while allowing the coil bobbins to be positioned for optimal fill factor.
Solution Approach 2:
The empty bobbins serve multiple functions: they provide insulation between adjacent coils, maintain the structural integrity of the armature, and enable optimal positioning of coil bobbins for maximum fill factor. This multi-functional element resolves the contradiction between space efficiency and insulation reliability.
3Productivity
If winding bobbins are placed close together to improve fill factor, then space efficiency is improved, but insulation properties between adjacent coils deteriorate leading to ground faults
Solution Approach 1:
Empty bobbins are positioned between adjacent winding bobbins as intermediary insulation structures. This allows the winding bobbins to be placed close together for high fill factor while the empty bobbins prevent electrical breakdown and ground faults by maintaining adequate insulation distance.
Data Source
AI summary
A bobbin structure of an armature of a three-phase motor having 6N (N is a natural number) slots and 3N coils per phase, the bobbin structure including: a main pole into which a winding bobbin around which a coil is wound is inserted; and an auxiliary pole into which an empty bobbin around which the coil is not wound is inserted. The main pole and the auxiliary pole are placed in a circumferential direction with respect to a rotation axis, and a contact portion where the empty bobbin and the winding bobbin are in contact with each other is formed on each of an outer peripheral side and an inner peripheral side of the slot formed between the main pole and the auxiliary pole.